WELCOME TO VOLCAN PUMPS INDIA
Inception of our original Factory now in Kolkata, in the year 1997 is the result of a group of highly qualified Engineers, who have all taken training in Austria & Germany and keep constant touch with the latest developments in pump industries in highly industrialized countries in Europe & U.S.A. This unit was initially set up for manufacturing special types / tailor made mainly import substitute pumps for Coal, Steel and Thermal Plants.
Quality Assurance Plan
Quality first of all, calls for consciousness in each and every member of the implementing team of a production company. Requisite care and actions are vital but come next to awareness. Cost of course plays its own role in quality. Based on sound design, better choice of materials and good workmanship quality is bound to follow. Qualification of Vendors too plays essential parts in quality.
Quality, by itself, is a large subject and hence cannot be dealt in a few pages. The subject Quality Assurance plan envisages only some of the essential on-the-job measures required at various stages of production of a Pump it outlines the following aspects but none of them in its entirety.
| All original Drawings of VOLCAN design being maintained and kept completely separated for all Models. |
| All new drawings and modifications being maintained separately for all Models. |
| Master drawing files are maintained for each model with assembly drawing showing part number and designation in full scale, all component drawings and bill of materials. |
| All drawings are scrutinized for correctness of dimensions. |
| A register being maintained with serial number of Pump, order acceptance file no, customer name and reference of subsequence modifications if any. |
| Pattern makers are competent enough. |
| Good quality of seasoned Teak wood is used to avoid deformation and damage of patterns. |
| Templates of Aluminum sheets are used for all curvatures e. g Impeller front and back shrouds. |
| There are a set of master Vanes for each Type of Impeller so that if any Vane is lost or damaged, it can be replaced by a new one from the Master Vanes. |
| Proper Shrinkage and machining allowance being kept it patterns according to material of Casting, C.I, S.S, G.M. |
| Proper storage of patterns in rack. |
| Record of Patterns in stores and with foundries. |
| 3.1 Visual inspection of castings before taking delivery from Foundry for the following |
| 3.1.1 Blow holes, cracks, distortion. |
| 3.1.2 Misrun, hard spots. |
| 3.1.3 Shrinkage at runners and risers. |
| 3.1.4 Smoothness of surface and sharpness of contours coal dust is mixed in proportion with sand to avoid fusing of sand into metal by forming a thin invisible layer of Co/Co2 gas. |
| 3.1.5 Comparison of weight with the standard weight. |
| 3.2 Proof machine casting for G.M and Steel alloys to avoid dispute in subsequent rejection due to casting defects such as blow holes, pin holes, cracks etc. |
| 3.3 Hardness and tensile strength testing, |
| 3.3.1 Poldi Test – easiest directly on the cast part. 180 -220 BHN for grade 210 & 260 for C.I casting depending on thickness. |
| 3.3.2 Test bar casted and machined for testing of hardness and tensile strength according to ISS in the laboratories. |
| 3.4 Chemical composition test in laboratories for Bronze and special steel Alloys. |
| 3.5 Surface annealing for steel casting to achieve machineability. |
| 4.1 Jigs and fixtures are used for all parts require concentric machining on both sides For fittings with matching parts as well as for drilling, Bearing Block, Casing etc. |
| 4.2 Tolerances are maintained as per drawing relevant Book mainly IS : 919 -61 recommendations for fits and tolerances. |
| 4.3 Precision measuring instruments like; a. Vernier Calipers (0.02mm) b. Micrometers inside and outside (0.01mm minimum) c. Height Gauge. d. Pitch Gauge. e. Slip Gauge. f. Cylinder Gauge. g. Limit Gauge – outside & Inside. h. Dial Test indicator. i. Bevel protector j. Scribing Block. k. Feeler gauge etc are used. |
| 4.4 Machines with fair degree of accuracy are installed and operated by skilled workmen. |
| 4.5 Special cares are taken to maintain clearance between Impeller Neck ring and Casing Neck ring as per drawings to achieve desired performance of Pumps. |
| 4.6 Smoothness of machined surfaces are maintained as indicated in the drawings by the degree of smoothness. Bearing locations are of Grinding finished. |
| 5.1 Proper sequences are maintained in assembling and dismantling the pumps. Since proper tolerances are maintained in machining and inspection done at every stage of manufacturing therefore, there is no difficulty in assembling. |
| 5.2 Mounting of antifriction bearings on shaft is done by preheating the Bearings in oil upto 100 – 120 C. |
| 5.3 Free movement of rotating elements checked and ensure at every stage of assembling. |
| 5.4 Proper quality, thickness and materials are used for sealing to prevent leakage at high pressure especially for multistage pump as well as to avoid metal to metal contract and jamming. |
| 6.1 Hydrostatic pressure testing of the complete pump assembly is done by a pressure of 1.5 times the shut-off head or 2 times the duty point head whichever is higher. Testing pressure is maintained for 5 minutes. Under pressurized condition, the assembly checked for leakage, seepage etc. |
| 6.2 Hydrostatic pressure testing is carried out invariably for all pumps irrespective of whether these are subject to inspection or not. |
| 6.3 Performance testing done According to IS : 5120 for Centrifugal Pumps and IS : 1710 for Vertical Turbine Pumps. |
| 6.4 Performance test is carried out for Pumps which are subject to inspection in presence of inspectors. For other pumps also, periodicals performance test is done to ensure the accuracy of patterns smoothness of casting surface which are likely to effect the performance of the pumps. |
| 6.5 For measuring head on Suction side Hg manometers are used. On delivery side only calibrated Bourdon type pressure gauge are used. |
| 6.6 For lower discharge, volumetric measuring tanks are used with stop watch for recording time to full up the tank. For higher discharge, full 90 V notch bed is available. However, Flow meters are also used for measuring the discharge directly. |
| 6.7 The pump runs at least for 30 – 60 minutes before full open or vice versa and the results computed using standard formulate to find out head, discharge, and efficiency and compare them with the characteristic curves. |
| 7.1 All surfaces are cleaned of dust, rust, grease, oil etc. |
| 7.2 Apply good quality putty as required. |
| 7.3 Apply foam base paint (Primer) by Brush. |
| 7.4 Apply final paint by Spray Gun. |
| 8.1 quality wooden packing Box match with the size and weight of the materials are used. |
| 8.2 Fixed up name plate including Make, Type, Capacity, Head, RPM, etc as per IS : 5120. |
| 8.3 Fixed up plate indicating direction of rotation. |
| 9.1 Fill up packing memo indicating all the items including foundation bolts, coupling, coupling guard, and other accessories etc, supplied in the packing box. Duplicate copy of packing memo are maintained in the stores for checking in case of complaint by the customer if any short supply. |
| 9.2 Operating and maintenance Instruction manual are supplied along with the pump in the packing Box. |
Our Clients
Contact
For any kind of query, contact us with the details below.
- +91 9830348211 / 7001126500
- info@volcanpumps.com
- TALBANDA INDUSTRIAL ESTATE, PHASE-I N.N. SAMADDER ROAD. PO. JUGBERIA,
WEST BENGAL 700110
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