Quality Control

Testing Facility

  • Chemical & Physical Testing : Materials used for equipments and structurals i.e. M.S.Plates, Bars, Seamless Pipes, Forgings etc shall be tested as per IS:2062 from approved laboratories viz. Fan Services, Nasik; Premier Electrodes, Nasik etc. All plates shall be ultrasonically tested.
  • Hardening & Stress Relieving Tests : Hardening & Stress Relieveing Tests for Wheels, Gear Box Castings, Gears and Pinions etc. is done as per IS:1570 from reputed laboratories viz. Unique Treatments, Nasik.
  • Welding All butt welds on structural members subject to tension are radiographically tested as per IS:4853 from Radiographic Services, Mumbai. All other non-load taking welds are to be visually examined and as per ASME - Section VII.
  • Ultrasonic Testing : As per IS:3664 for thickness greater than 50mm.

CONTROL PANEL AND ELECTRICAL TESTS :

  • Functional Test of the Control panel by simulating working condition. (a) Insulation Resistance Test (b) High voltage test with the following voltages :- 2.5 KV for one minute for the main power circuit. 1.5 KV for one minute for all control circuits.
  • Following tests shall be carried out in each of the resistance unit :- (a) Insulation Resistance Test (b) High voltage test at 2.5 KV for one minute (c) Temperature rise test to be conducted on the resistor unit on each type.

FACILITIES OF QUALITY CONTROL DEPARTMENT

  • Physical Lab And Non-Destructive Test (At Saico and Sub Vendors end) Tensile testing machine 40T FIE make. Rockwell Hardness Testing machine FIE make. Portable Hardness Tester. (PIN SHEAR - Model DHM & SHM) Ultrasonic flaw detector EIL make. Dye-penetrant test. X-ray film viewer and developing facilities. Metallurgical microscope.
  • Chemical Lab (At our Sub-Vendors End viz. Fan Services) Carbon & Sulphur apparatus. Single pan balance. Muffle furnace. Heater. Viscocity measurement. Distilled water unit.
  • Final Inspection (Saico) Gear box testing bed. Wheel assembly testing columns. Tachometer. Deflection Testing Instrument. (Facility Available)
  • Precision Measuring Instruments (Saico) Outside Micrometer 0.5 to 875-1000 mm. (0-300mm) Inside Micrometer 12mm. to 1000 mm. (0-300mm) Vernier depth gauge. Tooth Vernier calliper. Sound Detector for Gear Boxes Vernier calliper 0-1000 mm. (0-300mm) Dial bore gauges 18-35, 50-160, 160-250. Welding Gauge.
  • Load Tests Load, Overload and Deflection tests shall also be carried out at our works as per IS:3177 and IS:807. For overload test the crane shall be tested with 125% of safe working load on hoisting and cross traverse motions on the equipment. We have two fabricated stands to rest the Girders so as to carry out the load test upto 50 Tonnes.

The new era of crane manufacture incorporate latest technologies, viz;

  • Radio Remote Controls- These are used if the operator cannot work in the crane area.
  • Variable Voltage Frequency Drives - These are used to obtain variable speeds in any of the motions

Quality Plans

Sr.No
Component/
Operation
Characteristic
Checked
Category
Type/Methode
of Check
Extent
of Check
Acceptance
of Norm
Agency
P
W
V
 1.00 RAW MATERIAL
1.10
Structural Materials for Grinders, End Carriages, Crab and Platform 1 Sample per size of plate and other structurals
RM
Chemical & Mechanical
MA
IS : 2062
4
3
2
1.20
Rope Drum Seamless Steel Tubes 100%
RM
Acid Etching end
MA
IS : 3177
4
3
2
1.30
Brake Drum 1 Sample
Rm
Chemical Check
MA

IS : 1875
IS : 1030

4
3
2
1.40
Gears & Pinions 1 per size per Lot
RM
Chemical Check
MA

IS : 1570
IS : 970

4
3
2
1.50
Sheave / Pulleys 1 Lot
RM
Chemical Check
MA
IS : 2062
4
3
2
1.60
Wheels 1 Sample
RM
Chemical Check
MA
IS : 1570
4
3
2
 2.00 BOUGHT OUT ITEMS
2.10
Hooks 100%
BOC
U.T.
MA
IS : 3815
4
3
2
2.30
Wire Rope 100%
BOC
Examination of Reports for Braking Load
MA
IS : 2266
3
2
2
2.30
Rails / Sq.Bar 100%
BOC
Visual
MA
BS : 80A
3
2
2
2.40
Bearings 100%
BOC
Visual
MA
Mfgrs. Standard
3
2
2
2.50
Couplings 100%
BOC
Visual
MA
3
2
2
 3.00 IN PROCESS INSPECTION
3.10
Welding of Rope Drum 100%
Welding
RT of Joint
MA
IS : 4853
4
3
2
3.20
Welding of Box Grinders, Crab, End Carrige, L.T. Frames 100%
Random
Welding
Visual MPI / DPT
MA
IS : 822
IS : 3658
3
2
2
3.30
Welding
(Sounding)
100%
Welding
R.T. Butt welds in Tension
MA
IS : 4853
4
3
2
3.40
Gears & Pinions
a) U.T.
100%
U.T. Check
MA
IS : 3664
4
3
2
b) Hardness 100%
Hardness
MA
55-60 HRC
3
2
2
c) Dimensional
Accuracy
Random
Measurement
MA
IS : 4059
3
2
2
d) MPI Random
Crack Detection
MA
IS : 3658
3
2
2
e) Surface Finish Random
Surface Check
MA
1.6 microns max.
3
2
2
3.50
Gear Boxes
a) Sound Level
100%
Sound Check
MA
To be verified by Consultant
3
2
2
b) Leakage 100%
Check by Consultant
MA
To be verified by Client
2
2
1
3.60
Hooks 100%
Proof Load
MA
IS : 3815
4
3
2
 4.00 FINAL INSPECTION
4.10
Motors 100%
EC
Review of Routine TCs
CR
IS : 325
3
2
1
4.20
Cables 100%
EC
Review of Type Test / Routine Test
MA
IS : 694
IS : 554
IS : 9968
3
2
1
4.30
Control Panel, Wiring, Marking Input, Output sequence. 100%
EC
Visual check of fitting of components
CR
Electrical Drawing
IS : 3177
3
2
1
4.40
Components 100%
MC
Visual / rating
MA
Electrical Drawings
IS : 3177
3
2 1
4.50
Complete Assembled Cranes 100%
Crane
Visual & Checking of overall dimensions alignment & Completeness
CR
Final Tech. Spec / Approved Drawings
IS : 3177
3
2 1
100%
Load Test / Overload Test, Deflection Test, Speed & Current Measurements
CR
IS : 3177
IS : 807
Approved Drawings
3
2 1
4.60
Painting 100%
Surface preparation
MI
Client's Specs.
3
2 1
4.70
Lubrication 100%
Client'sSpecs.
3
2 1
  Abbreviation

 P :   Performed By
 W :  Witnessed By
 V :  Verified By

After Sales Plan

We have got two full fledge erection Teams equipped with motorized Winches of 10 T and 20T Capacities along with Derriks and other accessories. The teams are managed separate Electrical and Mechanical Engineers. At any given time, we are equipped to cater the erection of cranes at two different sites. In addition, we have appointed qualified Service Engineers to offer prompt Services to our Customers and attend their problems within 24 hours as far as possible.

We provide the Customers with detailed maintenance manual and also adequately train the personnels appointed by the client to handle minor breakdowns during the installation of the cranes. We also recommend maintenance of certain spares as stock so as to curtail the down time of the cranes therby leading to reduction in the production loss.