|
제품제조공정 |
|
Seamless Tube / Pipe
|
'U' Tube |
Welded Tube / Pipe |
|
|
|
|
| |
|
스테인레스
등급 |
|
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
|
|
| |
|
표준 사양 |
| |
|
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 |
|
| |
|
스테인레스 파이프 생산규격 |
|
|
| 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 |
|
| |
|
스테인레스 튜브 생산규격 |
| 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'자형 튜브 |
|
'U' 벤딩은 냉간공정으로 진행되며, 고객의 주문사양, 도면에 의해 Radius를 적용한다. 굽힘률과 6인치 발은 열처리로 응력제거하며, 아르곤개스통과처리로 내부산화를 막는다. 굽힘반경은 외경과 두께변화 면에서 관련표준에 따라 책정된다. 세 개의 다른부분에서 물리적성질과 내부구조를 체크한다. 염료투과시험으로 크랙및 웨이브에 대해 육안시험을 거친다. 각각의 튜브들은 누설확인을 위해 표준압력하에서 하이드로 테스트를 실행한다. 내부세정도를 확인키 위해 Cotton ball 테스트를 실행한다. 이후 피클링, 건조, 마킹, 포장을 거치게되며 모든 과정은 TEMA "C" 와 ASTM-A-688표준을 엄격하게 따른다.
|
|
| |
|
Bead removal 튜브 |
| 국제 표준에 따라서 Bead제거를 하며, Bead제거는 냉간으로 제조라인중 열처리 전 진행하며 풀림공정중 용접된부분은 더 빠르게 재결정화 및 균질화하게 된다. 이로써 내식저항이 개선되며, 확관성이 좋아지며, 관내 흐름을 좋게하며, 내부세정과 더 적은 스케일잔류를 가능하게 한다. |
|
| |
|
품질관리 |
|
Suraj의 모든 제품은 , 엄격한 국제표준에 의거하여 품질관리를 함으로써 고품질의 제품을 생산하고 있습니다. 모든 제작공정의 기준과 조건을 지속적으로 유지 및 개선에 충실히 임하고 있습니다.
모든 고객의 요구조건을 만족을 목적으로 ISO 9001 :
2000 , AD 2000 – Merkblatt / WO, and PED – 97 /23/EC에 따라서 제작된 품질관리기준과 표준지침을 우리는 계속 개선발전시키고자 노력한다. 품질관리시스템은 Stainless Steel
Seamless/Welded Pipes, Tubes and ‘U’ Tubes의 생산에 관련된 모든 부서와 작업에 적용된다.
관련 기술표준과 고객의 요구사양을 만족시키기 위해 가능한 최고의 품질을 얻어내기 위한 Suraj의 품질관리정책은 매우간략하다. 우리의 제품은 와전류시험, 수압시험, 자외선시험, 강도시험, Air under water test,
치수검사, 육안검사등의 다양한 시험을 거친다.
또한, 우리의 품질관리는 관련 화학성분 분석, 기계적성질 측정, 기계적, 금속성질측정, 치수허용측정등을 포함한다.
|
|
|
|
|
품질관리절차 |
|
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. |
|
|
테스트 장비 및 시험종류 |
| 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.
|
|
|
|
| |
|
보유 인증서 |
| ISO9001:2000ANSI/ISO/ASQ Q9001 |
|
AD2000Merkblatt W0 |
|
|
|
|
|
PED97/23/EC
|
|
Government Export House
|
|
Awards for Export Excellence
|
|
|
|
|
|
|
|
| |
|
납품 포장 방법 |
| 고객의 요청에 따라서, 아래의 방법으로 제품을 포장하게 됩니다. |
|
Wooden box packing
|
|
Crate packing
|
|
Bundle packing
|
|
|
|
|
|
|
|
| |
| Packing이 완료되면, 아래의 세가지방법을 이용하여 고객에게 운송합니다. |
| Open Top Container |
| LCL Cargo |
| Flat Bed Container |
)
)
)
)
)
)
)
)