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QUALITY  PLAN
( Inspection of In-process Material  )

QFM / QC /  08

REV. STATUS : 01

Dated : 03/12/2003

     
S. No Product Operation/ Stage Checking  Parameter

Method of Checking

Sample  Size Frequency IMTE Used Acceptance  Criteria
1. Pipe Fittings Casting Dimensions Manual 2 pcs / item Daily Vernier Calliper As per  SS . QFM
/ QC /  01
Wall  thickness Manual 2 pcs / item Daily P– type Caliper As per  SS . QFM
/ QC /  01
Cracks Visual 100%/item Daily -------- No  cracks
Unfilled Visual 100%/item Daily -------- No  unfilled
Deep  pits Visual 100%/item Daily -------- No  deep  pits
Shifting Visual 100%/item Daily -------- No  shifting
Deposits Visual 100%/item Daily -------- No  deposits
Chemical  Test Carbon  contents Lab Test 10 – 20 gms Once in  4 months Lab. test (outside) 2.7 – 3.2 %
Silicon contents Lab Test 10 – 20 gms 1st & 3rd  Heat Lab test 0.8 – 1.2  %
Heat Treatment Temperature Manual Each  Furnace Each C.U. No Pyro – meter Min.850°C ,Max  950°C for 24  hrs
Compression Test Malleability Bench vice 9 pcs Each C.U. No. Vernier Calliper 5 % upto 2" Ø & 3 %  above 2" Ø
Mechanical  Test Elongation / UTS Out side agency 3 pcs test bar Each C.U.No. Tensile testing m/c Min.6%@ 300 Mpa  IS: 14329 - 1995
Stone  Grinding Unwanted material Visual 100 % / item Daily ---------- Free from  unwanted material
Shot Blasting Surface  cleaning Visual 100 % / item Daily ---------- Free  from  rust  etc.
Galvanizing Mass of Zinc Coating Dip Test 3 pcs / C.U No Daily Lab test Min.610 gms / m²  IS: 4759 – 1979
Zinc  Coatings Surface smoothness Visual 100 % / item Daily ---------- Smooth  surface
Flux  ash Visual 100 % / item Daily ---------- No flux ash
Bare patches Visual 100 % / item Daily ---------- No  bare  patches
Pimples Visual 100 % / item Daily ---------- No pimples
Lumps Visual 100 % / item Daily ---------- No lumps
Rust strains Visual 100 % / item Daily ---------- No  rust  strains
Excess  / less deposits Visual 100 % / item Daily ---------- No excess  /  less  deposits
Chamfering External / Internal threads Visual 5 pcs / item Hourly ---------- No item without  chamfer
Machining Threading Manual 5 pcs / item Hourly Thread Gauge ± 1¼  thread as  per  IS: 8999 – 1979
Damaged  threads Visual 5 pcs / item Hourly ---------- No damaged  threads
Alignment Test Straightness / 90° Manual 5 pcs / item Hourly Jigs 180°± ½°,  90°± ½° IS : 1879 – 1987
Pneumatic Test Air–leakage Compressed air 13 pcs / item Daily Pressure dial gauge No leakage @ 10 Kg/cm² IS : 1879 – 1987
Hydrostatic Test Water–Leakage Hydraulic pump 13 pcs / item Daily Pressure dial gauge No leakage @ 21 Kg/cm² IS : 1879 – 1987
Barrel Oily-surface cleanliness Visual 100 % / item Daily ---------- Free  from  oil
Remarks :- 1.  All  dimensions  are in  mm.  unless  otherwise  specified.
                 2. Calibrated  instruments  are used  for  inspection.
                 3. 100%  pneumatic  test is  performed  for  gas fittings only.