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Quality Policy
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RAHUL GROUP is committed to consistently supply stainless steel, carbon steel and allied Products to the satisfaction of customers through continual improvement in methods, processes and resources to comply with TUV NORD ISO 9001:2015, ISO 14001:2015, ISO 45001:2018, PED 2014/68/EU & AD 2000 Merkblatt W0, 3A, ASME BPE & BIS certified company. We constantly strives to improve the quality of life of the communities we serve through excellence in all facets of its activities.
Our motto is to provide quality approved range of Nickel Alloy, Super Duplex, Duplex, Stainless Steel - Seamless & Welded Tubes, Pipes, 'U' Tubes & Fittings and allied products. Owing to this reason, we manufacture these products using premium quality steel and other basic material, which is procured from the most reliable and trustworthy vendors of the market. All our products are manufactured employing prevailing technologies in compliance with the norms and standards of the industry.
Quality Assurance
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RAHUL GROUP carries a Quality Management System certified in accordance with the ISO 9001:2015 standard. The well-deserved certification is the result of high and consistent standards of processes, which is reflected in the high quality of the products.
An independent quality assurance department is responsible for work procedures required to ensure that manufacturing processes are carried out in accordance with international technical delivery conditions given in ASTM, ASME, EN, IS and customer specifications.
To guarantee high quality, we procures raw material from top-notch vendors of international repute. The manufacturing is carried out under strict process control and monitored throughout the production process to ensure total conformity to requisite specifications.
All through the process and finally before dispatch, uncompromising and stringent tests are carried out as per the standards specifications or customer specific requirements. Every single piece of material is subjected to a thorough visual inspection by trained staff to detect dimensional inaccuracies, surface imperfections etc
To ensure complete identification and traceability even after supplies are effected, all the information as required by the standards, i.e. brand name, size, grade, specifications, heat number is marked on all the pipes and tubes
Quality Assurance generally aims how to address quality related errors and how to improve those errors before occurring. The plan helps in eliminating defects. We ask our Customer to give the feedback and helps in improving the business process.
QUALITY PLAN FOR SEAMLESS PIPES & TUBES
| Sr. No. | Product Realization Stage | Parameters to be checked | Acceptance Criteria | Measuring Device / Ref. | Sampling Frequency | Responsibility | Record |
|---|---|---|---|---|---|---|---|
| 1 | Customer Requirements Review | Technically & Commercially Feasible. | Technically & Commercially Feasible. | WMK01 | Each Customer Order | DIR / MK in charge | Enquiry Register |
| 2 | Purchasing | Requirements properly defined | Requirements properly defined | -- | Each Purchase Order | PS In charge | Purchase Order Supplier rating – FPS 04 |
| 3 | Planning | Availability of R.M., tools, dies, machines | -- | Stock statement, list of dies, machines | Each Work Order | Planning In charge | Planning Sheet – FPLG 01 |
| 4 | Receiving Inspection | Dim: Width, Thickness | As per tolerance chart | V.C., Micrometer | At each coil | Q.A. Manager | R.M. Insp Report – FQA 02 |
| Chemical Properties | As per relevant standard | Outside Lab | One sample / Heat no. | ||||
| Physical Properties | As per relevant standard | UTM, Hardness Tester | -- | Outside Lab Test Report – FQA 06 | |||
| Visual Inspection | Cracks, Surface Finish, Waviness, Edges | Visual | 100% | R.M. Insp Report – FQA 02 | |||
| 5 | Draw Bench | Thickness, OD, Length | As per relevant standard or customer requirement | Micrometer, Vernier, Measure Tape | 5Pcs /Lot | Operator / Inspector | Pilgher / Draw Benchreport – FPR 07 |
| 6 | Solution Annealing | Hardness | As per relevant standard or customer requirement | Hardness Tester | 1 pc. Per Heat | Operator / Inspector | Annealing Report – FPR 03 |
| 7 | Straightening | OD, Length, Straightness | As per relevant standard or customer requirement | Vernier, Measure Tape, Steel Rule | 5 Pcs /Lot | Operator / Inspector | Straightening report – FQA 04 |
| 8 | Hydro Testing | Leakage | No leakage | Pressure Gauge | 100 % | Operator / Inspector | Hydro Test Report – FQA 05 |
| 9 | Pickling | Scale | No Scale | Visual | 100 % | Operator / Inspector | Pickling Register – FPR 08 |
| 10 | Final inspection | OD, Thickness, Length, Visual | As per ASTM / EN | Vernier, Micrometer, Measure Tape, Visual | 100% | QA In charge | Final Insp. Report - (Dim. + Visual) – FQA 05 |
| 11 | Product Analysis | Physical, Chemical | As per ASTM / EN | UTM, Hardness Tester, Outside Lab | As per sampling Plan | QA In charge | Material T.C. |
| 12 | Packing & Dispatch | Proper Packing | As per Customer Req. | -- | 100 % | Packing Supervisor | Invoice |
QUALITY PLAN FOR STAINLESS STEEL WELDED PIPES & TUBES
| Sr. No. | Product Realization Stage | Parameters to be checked | Acceptance Criteria | Measuring Device / Ref. | Sampling Frequency | Responsibility | Record |
|---|---|---|---|---|---|---|---|
| 1 | Customer Requirements Review | Technically & Commercially Feasible. | Technically & Commercially Feasible. | WMK01 | Each Customer Order | DIR / MK in charge | Enquiry Register |
| 2 | Purchasing | Requirements properly defined | Requirements properly defined | -- | Each Purchase Order | PS In charge | Purchase Order Supplier rating – FPS 04 |
| 3 | Planning | Availability of R.M., tools, dies, machines | -- | Stock statement, list of dies, machines | Each Work Order | Planning In charge | Planning Sheet – FPLG 01 |
| 4 | Receiving Inspection | Dim. – Width, thickness | As per tolerance chart | V.C., Micrometer | At each coils & | Q.A. Manager | R. M. Insp Report – FQA 02 |
| Chemical Prop. | As per relevant standard | Outside Lab | One sample /Heat no. | ||||
| Physical Prop. | As per relevant standard | UTM, Hardness Tester | - | Outside lab. Test report – FQA 06 | |||
| Visual | Cracks, surface finish, waviness, edges | Visual | 100 % | R. M. T. C. Review | |||
| 5 | Tube Mill | Thickness, OD, Length | As per relevant standard or customer requirement | Micrometer, Vernier, Measure Tape | 5 Pcs / Lot | Operator / Inspector | Tube mill report – FQA 03 |
| 6 | Solution Annealing | Hardness | As per relevant standard or customer requirement | Hardness Tester | 1 pc. Per Heat | Operator / Inspector | Annealing Report – FPR 03 |
| 7 | Straightening | OD, Length, Straightness | As per relevant standard or customer requirement | Vernier, Measure Tape, Steel Rule | 5 Pcs / Lot | Operator / Inspector | Straightening report – FQA 04 |
| 8 | Hydro Testing | Leakage | No leakage | Pressure Gauge | 100 % | Operator / Inspector | Hydro Test Report – FQA 05 |
| 9 | Pickling | Scale | No Scale | Visual | 100 % | Operator / Inspector | Pickling Register – FPR 08 |
| 10 | Final inspection | OD, Thickness, Length, Visual | As per ASTM / EN | Vernier, Micrometer, Measure Tape, Visual | 100% | QA In charge | Final Insp. Report (Dim. + Visual) – FQA 05 |
| 11 | Product Analysis | Physical, Chemical | As per ASTM / EN | UTM, Hardness Tester, Outside Lab. | As per sampling Plan | QA In charge | Material T.C. |
| 12 | Packing & Dispatch | Proper Packing | As per Customer Req. | -- | 100 % | Packing Supervisor | Invoice |
Quality Assurance Plan
Incoming Raw Material
| Sr. No. | Process Description | Ref. Documents Standards | Characteristic to be checked | Samples quorum of size/inspection | Instrument equipment used for testing | Acceptance criteria |
|---|---|---|---|---|---|---|
| 1 | Round Bars/ Seamless Pipe (Mother Hollow)/ Coils | Purchase Order/ Specification |
• Dimension • T.C. Verification (Lab test Report) (if required) • Packing Condition • Weight • Defects if any |
Sample / Heat | Vernier, Micrometer, Chemical Analysis, Tensile Testing Machine (Brinell Rockwell), Hardness Testing Machine | Confirm to Specification 100% |
Stage wise Inspection
| Sr. No. | Process Description | Ref. Documents Standards | Characteristic to be checked | Samples quorum of size/inspection | Instrument equipment used for testing | Acceptance criteria |
|---|---|---|---|---|---|---|
| 2 |
I) Hot Piercing Bars to Seamless II) Seamless Cold Drawing III) Welded Tube forming & Welding |
As per Work order/ Specification |
Dimensions check Diameter (Ovality) x Length x Thickness • Weight • Defects if any |
3 Samples from each Raw Material | Universal testing machine UIN40-T Make "UTS", Microscope, Vernier, Micrometer & Measuring Tape | Dimensions acceptance as per order Confirm to standard samples as per details |
| 3 | Solution and/or Bright Annealing | Temperature as per ASTM / EN & EN Standard |
• Temperature • Hardness • Cooling • Water Quenching |
2 Sample per lot / 2 Sample per heat | Digital Graphic, Temperature Recorder, Digital Temperature Indicator & Temperature Controller, Metallurgical Microscope, Brinell Rockwell Hardness Tester | |
| 4 | Straightening | Straightening as per specification | Check straightening of Pipes & Tubes | First 2 pipes of each size lot | Roller Straightening Machine, Micrometer, Visual Observation | Straightening as per specification standard sample |
| 5 | End Facing Squaring & Beveling | Burr Free Squaring / Beveling with Proper V-Shape | 100% Visual inspection | Abrasive Polishing as per standard sample | Confirm to specification / requirement | Straightening as per specification |
| 6 | Hydrostatic Testing / Eddy Current Testing / Ultrasonic Testing | As per ASTM / EN standard | Leakages | 100% | Hydraulic Pressure Tester | No Leakage |
| 7 | Picking & Passivation | As per required ASTM / EN standard |
• Scale removing inside • outside surface area |
100% | Visual Observation requirement | Confirm to requirement |
| 8 | Final Inspection Physical / Chemical Testing | As per applicable standard | Visual Dimension, Physical & Chemical | 100% (or) as per ASTM / EN standard | Micrometer, Vernier, Universal Testing Machine, Molly Detector & Caron sampling at random spectra / wet method | Confirm to requirement |
| 9 | Marking (as per) customer requirement / standard marking | As per requirement |
• Spell check • Details verification |
100% Confirm on first two sample & continue | Inkjet machine / Electro Etching co-relation of heat no size Grade etc. with Test certificate | Confirm to requirement |
| 10 | Packing & Delivery | As per customer requirement | Packing quality Tightness of packing | 100% confirm to requirement and release for | Box Crate, Polythene, Hessian Cloth | Packing confirm to customer requirement |
Quality Control - Test & Inspection facility
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" Quality control is a procedure or set of procedures which intended to ensure that manufactured products adheres to a defined set of quality criteria or meets the requirements of the customers."
RAHUL GROUP has Quality Control Department independent of manufacturing shop. Our Products undergoes a series of comprehensive mandatory & customer specified supplementary and special tests at its in-house testing facilities by its qualified personnel. We are equipped with all latest testing facilities.
Product testing at recognized third-party test laboratories can also be offered.
base64_encode This has been made possible by continuous innovation and focused vision of the management. Our team of qualified and experienced engineers at all levels that thrive to produce the best quality of Products.
AT RAHUL GROUP all products are manufactured under strict process control and monitored throughout the production process. They are subjected to a number of checks to ensure total control conformity to specifications.
Inspection & Testing Facilities:
01. Chemical Analysis
XRF Mobile spectrometers. (PMI Testing Machine)
Optical Emission Spectrometers, 32 channel
02. Mechanical/ Physcial Testing :, Below Test are carried out in full compliance with relevant standards, i.e. ASTM A-1016 and A-999 norms
Tensile
Flattening
Flaring
Flange
Hardness
Reverse Bend
Reverse Flattening
Impact
Root Bend
Face Bend
Residual Chloride Salt Contamination
Drift Expansion
03. Fully equipped laboratory for
Chloride Contamination Testing, Bath Analysis Testing,
Die Penetrant Test & Residual Stress Measurement.
Corrosion IGC Test (Inter Granular Corrosion Test as per A-262 practice A B C or E
04. Micro & Macro Structure Examination / Analysis & Grain size determination.
05. Hydro Testing –SS Straight & U-Tubes and CS Pipes - 100% Hydrostatic Testing is carried out according to ASTM A 450 & 530 & ASTM - A 1016 norms to check tubes for leakage
06. Air Under Water Testing – Straight Length upto 30 Meters - Tubes are internally pressurized with clean and dry compressed air and being submerged in clear water to check any evidence of air leakage
07. Ferrite Content & Surface Finish
08. Fiberscope – Inside surface checking of Tubes having outside diameter 4.7 MM and above
09. Surface Roughness Testing
10. Non Destructive Testing offered
Eddy Current Testing - To detect homogeneities in subsurface, eddy current testing is carried out using Flaw-mark Testing System
Ultrasonic Testing with full body thickness measurement
Real Time Digital Radiography Testing
Conventional Film Radiography
11. Visual Inspection
After passivation, every single length of tubes and pipes is subjected to a thorough visual inspection by trained staff to detect surface flaws and other imperfections.
12. Marking
To ensure complete identification and traceability, all the information as required by the standards i.e. Brand Name, Size, Grade, Specifications, heat No., / Lot No. is marked on all the pipes and tubes by using the latest inkjet marking machine.
13. Third Party Inspection
We are engaged in providing our clients material with inspection of any third party. The third party inspection provides quality assurance for buyers. In this process, we take care of material certification, design review and certification of equipment. The quality assurance services includes vendor audits and engineering inspection of mechanical and electrical equipment.
The Inspection Agency can be nominated by client or we can arrange the third party inspection by various world class reputed agency such as below and more:
Inhouse Inspection & Testing Equipments
| Sr. No. | Name Of Machine | Capacity | No. of Machines | Work Description |
|---|---|---|---|---|
| 1 | Universal Tensile Testing Machine | 40 KN | 1 | To obtain the mechanical properties of finished tubes & pipes and testing for flaring, flange test, flattening, R.flatting, reverse bending |
| 2 | Universal Tensile Testing Machine | 60 KN | 1 | To obtain the mechanical properties of finished tubes & pipes and testing for flaring, flange test, flattening, R.flatting, reverse bending |
| 3 | Hardness Testing Machine | HRB, HRC and BOT 45TSCALE | 1 | Hardness tester is used for measuring hardness values of tubes & pipes. |
| 4 | Hydrostatic Test Machine | 6 mm OD to 273 mm OD 6 inch to 10 inch |
3+1 | All hydrostatic test machine is used for carried out on finished tubes / pipes to check the tube for any leakage under elevated hydraulic water pressure as per specification or customer requirement. |
| 5 | U' Bend Hydrostatic Test Machine | 12.7 mm OD to 50.8 mm OD | 2 | U' Tubes hydrostatic test machine used to carried out on tubes / to check the leakage under elevated hydraulic water pressure as per specification or customer requirement. |
| 6 | Air Under Water Test (Pneumatic Test) | 6 mm OD to 30 mm OD | 1 | Pneumatic Test is carried out to check any leakage in the tube by air pressure under water. |
| 7 | Eddy Current Testing Machine | 8 mm OD to 114.3 mm OD | 1 | This is the non-destructive test carried out to detect the surface defect/pin holes on the outside diameter or inside diameter of the tube. |
| 8 | Polishing Machine | DISC DIAMETS 200mm | 3 | Single 200 mm diameter disc polisher with variable speed facility for polishing of test pcs. |
| 9 | Spectrometer | 35 Elements Percentage Analysis | 1 | Spectrometer which is used for in-house product analysis. It can measure up to 26 elements and gives the result of any sample within 60 seconds. It gives us very fast & highly accurate results. |
| 10 | Spectro Mobile For PMI Testing | 7 Elements Percentage Analysis | 1 | This instrument make analyser for pmi and quality control/assurance. |
| 11 | Dye Penetrant Test | Detect Micro Crack | 10 Kits | Dye Penetrant Test is carried out on tube & pipe surface to detect cracks, flaws or any type of defects. |
| 12 | Surface Roughness Tester | Upto 350 Microns | 1 | Test is carried out for measuring roughness of the tube & pipe for outer surface. |
| 13 | Chemical Testing Laboratory | Practice 'A' & 'E' | 1 | Established in UNIT - II, facility to carry out day to day testing of different solution used in pickling department & IGC testing practice 'E' as per ASTM A-262. |
| 14 | Visual & Dimension Inspection Skids | Visual Inspection | 20 PAIR | Inspection is carried out for any type of surface defect, or scratch on the surface of tube/pipe, dents and the dimensional inspection is carried out with calibrated measuring instruments for product dimensions are within tolerance requirements. |
| 15 | Microscope | Magnification 100 X to 400 X | 1 | Involves grain structure examination as per specification (Microstructure as per E-112). |
| 16 | Dial Vernier Caliper | 8 inch | 5 | Measure diameter & thickness of the tubes & pipes. |
| 17 | Ultrasonic Thickness Gauge | 0.75 mm to 300 mm | 2 | This instrument measures the thickness at any point of the tube & pipe with accuracy of 0.1 mm. |
EHS Policy
Safety Starts With Me, Together We Care
RAHUL GROUP strictly follows and believes in NKOM's 5 Key Safety Principles:
If safety is expensive, disasters cost more
Value everyone's safety
Zero tolerance for incidents
Recognise safe behaviour
Passion for Health, Safety & Environment (HSE)excellence
RAHUL GROUP is committed to statutory requirements related to environment, health & safety and to prevent pollution, injury & ill health through
continual improvement in processes, practices & EHS awareness by involving people & interested parties through effective communication & training for conservation of natural resources like water, energy & materials.
We Believe in Health, Safety and Environment Policy to ensure that all the work processes are carried out in a safe manner in compliance with all applicable codes, standards, rules and regulations and to protect employees, equipment, property, third parties and the environment from injury, loss and damage.
In the implementation of the policy, all the employees have a contribution to make and summarize as follows:
The Management
Provision of a safe working environment for all employees.
Arrange appropriate training for employees.
Notify employees of the hazards associated with the work processes and/or update them regularly.
Provision of appropriate personal proactive equipment.
Discipline those employees who violate safety instructions, safety procedures.
Ensure that all accidents are reported and that the causes are eliminated.
The Employees
Report all accidents, near misses or hazardous conditions to their immediate supervisors or to the management as well.
Use the correct tools and equipment’s for the job in the right way.
Take all the proactive measures and precautions to protect themselves and their fellow employees.
Understands and follow safety instructions given by their safety engineer, supervisors, foremen as well as safety officers/engineers.
Summary
By working together, the management and the employees will succeed in maintaining the HSE Policy/Programme conforming to the highest standards, for the safety and benefits of all concerned.
Thus, we are committed for continual improvements in the processes, by prevention of pollution and improving the health, Safety and Environment performance among the community and interested parties, providing safe work environment with the help of educated, trained and dedicated personals, reviewing implemented HSE System periodically.
Contractors Safety Code
Applicability:
Any Contractor/Labour/supplier/service provider/vendor who desires to carry out any type of job with or without material/machinery/equipment at RAHUL GROUP premises.
Objective:
To ensure Legal compliance under the Factories Act. It is the duty of RFEL as a Principle Employer to ensure health & safety of all direct or indirect employees and smooth functioning of project activity.
General Rules:
01. Contractor shall take suitable Insurance Policy to cover all workmen, supervisory staff and his sub-contractors under Workman's Compensation Act.
02. If the strength of employees is within 30 persons, Contractor shall depute one person who is overall responsible for ensuring safety of his employees working at site. If the employee strength exceeds 30 persons, vendor has to depute one safety officer who will be overall responsible for ensuring safety of his employees. Responsible person has to work in consultation with plant safety department.
03. Contractor shall take all Safety measures to avoid accidents strictly in accordance with Factories Act & Gujarat Factories Rules.
04. Vendors shall pay special attention on the following.
Fencing of their equipment, plants, platforms, openings, trenches etc.
Positive Machine guarding (360) for moving machinery, V- Belt, conveyor system, gear mechanism, reciprocating machine etc
All portable tools should have insulated handle for operation, proper earthing & guarding mechanism. All portable electrically operated tools to be inspected & certified by our Safety Department before putting to use. Any loose connection/open wire ends/breakage in the wire will not be allowed.
You have to produce the valid test certificate duly certified by competent authority for lifting equipment used in the plant premises for lifting job.
05. Contractor shall follow the work permit guideline prevailing at the plant for Hot work/ Cold work/Confined space entry/ Digging/ Heavy Equipment Lifting permit.
06. Contractor shall provide Safety Helmets, Safety Shoes to all labours. Contractor shall provide other Personal protective equipment like Safety Belts for working at height, Gloves, Face Shield, Welding Glass Shield etc. as per job demand. Contractor has to follow the instruction of safety department for providing personal protective equipment’s in specific cases.
07. All waste / debris / empty containers / plastic bags / used packing material / small pieces of material etc. are to be removed from the work place immediately after the job is over or at the end of shift whichever is earlier at designated place in consultation with Project Team & plant administration.
08. Contractor shall arrange to give safety training to his Employees / Labours for prevention of accident and make aware about standing orders prevailing at the plant in consultation with plant safety department.
09. Maintain proper House Keeping at the work place.
10 .Avoid any unsafe condition & if such unsafe condition observed, it should brought to notice of safety department immediately.
11. Do not tamper with any equipment set up/system/electrical switch board/piping/fire hydrant points/apparatus/ lift or moving machine installed in the factory area.
12. It is forbidden to employ children and under age workers inside the factory premises as per the Labour Law of INDIA.
13. Smoking & carrying match box / lighter or material that produce naked flame, flammable material like Petrol/ Kerosene or any other source which may be major source of fire is strictly prohibited in the factory. Such material should be deposited at factory gate. Necessary gate pass may be obtained if essential.
14. Do not perform undefined work without proper instruction like use of JCB machine, Crane.
15. Horseplay/Mischief/Misbehavior with others/Committing violence etc. is strictly prohibited and strict action will be taken.
16. Compressed air must not be used to blow out dust /dirt from cloths / body.
17. Keep the safety & firefighting equipment’s free of obstruction as these are required to be used in case of an emergency.
18. You have to maintain first aid kit in your custody
19. You have to use company's resource like water/power in economic way.
20. You have to ensure that the general facilities like Drinking water, W/C should be used properly by your employees.