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Quality Assurance

Falbin Engineering Private Limited s a TQM policy, with the aim to serve superior quality range to the customers. The policy we follow has been approved for ISO 9001:2008 & NABCB certification by BSCIC. As per this policy, we use superior grade material to develop all type of Process Equipments such as Reactors, Vessels, Heat Exchangers, Condensers, Dryers etc. For high quality production, we source and use  IS 2062 standard Stainless Steel, Boiler Quality Plate and many other material. To make a commendable range, our experts keep in mind guidelines & codes of IS 803,IS:10987:1992, API:650 & ASME SEC:VIII- Division 1, TEMA Standards & PESO Rules. Our company has been regularly supplying an impressive gamut due to making the same after design approvals from renowned design consultants like PDIL, EIL, Linde, UDHE & TUE, etc. Further, we have maintained a quality checking cell, where our products are examined using advanced testing facilities. Following are the tests that are conducted on our range:

  • Hydro Test
  • Pneumatic Test
  • 3rd Party for Thickness
  • RA Test
  • MOC Test by Moly & PMI
  • X- Ray-Radiography & UT Test
  • Plate for Shell /Dish-Chemical and Physical Test of RM
  • Nozzle Flanges, Hardware & Plates- Manufactures TC
  • Fasteners- Chemical, Tensile, Hardness & Proof load, Mfg TC
  • Qualification of Welding Procedures

In addition, our Quality Assurance Procedure makes us conduct following tests:

QUALITY ASSURANCE PLAN

SR NO

DESCRIPTION

EXTENT OF TEST

INSPECTION BY

REMARK

1

Verification of Purchased Order issued By Customer for Raw Material Indenting N Procurement

Verification with our offer N details of final negotiation done with customer

Mktg & Planning Department Jointly

Material Delivery Long Term N Short Term worked out for the procurement with external agencies if any involved for approvals etc

2

Preparation, Checking N approval of GA & Fabrication Drawings (IN HOUSE)

Verify with the detail did with customer during submitting Tech offer N any drawing /ref received with inquiry

Design, Planning N Mktg Department Jointly

Important Remark or Customer Special Comments needs to Marked on G A Drg. N Time line : Max 3 Days

3

Checking N Approval of G A Drawings / Fab Drawing / Design Calculation / QAP / Bar Chart etc from Customer

Minute details, Block Diagram with all detail N Revision / Date should mark on each drag.

Approval from Consultants / Project / Engg Department of Customer

Mktg (FEPL) Should submit the Drawing to Customer through their Purchase Department of Customer N Time Line for approval: 3-5 Days Max.

4

Special Remark / Approved Drawing from Customer

Time taken by Customer for the Approval of Drawings

Design, Planning N Mktg Department Jointly

Original Copy should file in customer file , One Photocopy (Control Copy ) with Design N Planning Dept & One Copy should sent to Fabrication Department

5

Material Procurement with Inspection N Metal Testing from external agencies

Identification of Raw Materials (Plates,Pipes,Structure etc)

Joint Responsibility of Planning ,Purchase, Inspection N Stores Department

Material Test Certificate to verify N one photocopy should sent to customer by Mktg for arrangement of Inspection from customer

(i)

Plate for Shell /Dish : Chemical N Tensile Test of RM




(ii)

Nozzle Flanges , Hardware N Plates : Manufactures TC




(iii)

Fasteners : Chemical, Tensile, Hardness N Proof load, Mfg TC




6

Raw material Identification N Physical verification at site

Dimension, Chemical N Molly Test in Case of SS Material

Joint Responsibility of Quality Control - Inspection N Stores Department

Material to be issued for fabrication after verification

7

Qualification of Welding Procedures




(i)

Long Seam Set Up

100%

Internal Q C Dept

Random Check By Inspection Agencies / Customer

(ii)

Long Seam back chip + DP

100%

Internal Q C Dept


(iii)

Circumferential Weld Seam Set Up

100%

Internal Q C Dept


(iv)

Circumferential Weld Seam back chip + DP

100%

Internal Q C Dept


(v)

Dimensional Check of Shell Sections / Bottoms /Cones / If Any

100%

Internal Production

Random Check By Q C Dept

(vi)

Nozzle Pipe to Flanges Setups

100%

Internal Production

Random Check By Q C Dept

(vii)

Setup of Nozzle connections

100%

Internal Production

Random Check By Q C Dept

(viii)

Back Chip N DP Test of Nozzle

100%

Internal Production

Random Check By Q C Dept

8

Non Destructive Testing like RT,MPT,UT,DPT etc.

Random

Check By Q C Dept

Random Check By Inspection Agencies / Customer

9

Witnessing of pneumatic test of RF Pads

100%

Internal Production

Random Check By Q C Dept

10

Internal / External Examination for Final Workmanship

100%

Internal Production N Q C Dept

Random Check By Inspection Agencies / Customer

11

Final Dimensional Check

100%

Internal Production N Q C Dept

Random Check By Inspection Agencies / Customer

12

Witnessing of Hydro Test N Water Fill Test

100%

Internal Production N Q C Dept

Random Check By Inspection Agencies / Customer

13

No load N Load Trial Runs in case of Reactor / Hydrogenation Reactor / Pressure Vessel etc

100%

Internal Production N Q C Dept

Random Check By Inspection Agencies / Customer

14

Preparation of As Built Drawings of Equipment like Tank, Vessel, Reactor , SPM etc

100%

Joint Responsibility of Design, Production N Q C Dept

Random Check By Inspection Agencies / Customer

15

Documentation

100%

Joint Responsibility of Design, Production N Q C Dept

Random Check By Inspection Agencies / Customer

Products We Offer

We are known for manufacturing, supplying and exporting Process Equipments for all Processing Industries :

  • Chemical and Pharmaceutical Process Equipments
  • Food and Pharmaceutical Process Equipments
  • Fertilizer Process Equipments
  • Petro Chemicals & Refinery Process Equipments
  • Reactors
  • Storage Tanks (MS, SS & BQ)
  • Condenser
  • Columns
  • Re-boilers
  • Heat Exchanger
  • Blender
  • Dryers
  • DM & RO Water Storage Tanks (Electro Polish)
  • Heating & Cooling Systems
  • Mixers
  • MS / SS Flanges
  • MS/SS Lined Flanges
  • Pre Fab Building
  • All kind of Vessels

Our Manpower

The professionals working with us are our strength and a major reason behind attained tremendous growth & popularity in the market. Each member of our team is appointed after clearing out conducted stringent exams and interview sessions. To take the firm to the heights of success, our experts work with complete honesty, sincerity, punctuality and dedication. Following are the highlighted detailed of our team:

Sr.No.

Skill

No.

Qualification

Experience

1

Design & Production Engineers

01

B E Mech.

1- 30 Years

2

Production Manager

01

B E Mech/Diploma Engineer

1-35 Years

3

Quality Assurance

01

ITI & NDT (Level II)

1-10 Year

4

Supervisor /Foreman

02

Diploma/Engineers

1-25 Years

5

Commercial Staff

02

B.Com/B.A.

5-7 Years

6

Qualified Fabrication Fitter

03

ITI or Equivalent

1-15 Years

7

Qualified Welders

04

ITI & IBR

5-15 Years

8

Grinder man, Rigger, Helper

07

ITI & Exp from Relevant Field

1-15 Years

Infrastructure

A spacious and architecturally designed infrastructure set up is owned by us for having streamlined execution of trade activities. It is built on a sprawling area and has interlinked wings of manufacturing, research & development, designing, storage, quality checking etc. Below tabulated are some of the highlights of our set up:

Shop/Plot No.

C-2,Shankar Patel Ind. Estate, Village, Manjusar

Clear Height below the crane hook

4.0 & 6.0 Meters

Covered area for Manufacturing / Fabrication

3000 Sq.Ft. & 6000 Sq.Ft.

Crane capacity

EOT : 5 MT &Future :10 MT

Plot Area

4500 Sq.Ft. & 7000 Sq.Ft.

Code followed

IS 803 / IS 10987 /ASME / TEMA /PESO & Good Manufacturing Practices

Design Facilities

In House & Will Take Supports from External Based on Need

Material Handled

IS 2062

CS

B Q

SS 409 / SS 321 / SS304 / SS316 & SS 316L

Any other

Connected Load

50 HP

Water Availability

Own Bore Well

Water Quality : Drinking/Good

Design Facility

For us designing of products is an utmost important process, in this stage, basic layout is set, following which the range is built. To bring innovative range and keep the high standard our product-line, we have maintained following designing facilities:

Design Facility

Details

Auto Cad 2013

For 2 D & 3 D View & Drafting

Chem. Cad

Chemical Process Equipment Design

M S Project

Detail Planning of Project Activity

PDMS

Plant layout includes Civil & Mechanical- Piping ,Electrical, Equipment Layout and HVAC & Process design (PFD/P&ID)

Solid Work

Total detailing like Inside, Out Side 3D View of M/C

Manufacturing Facility

To convert the design layout into final products, we have maintained several facilities in our production cell. Our company has been easily catering to the bulk or sudden demands of market due to support of production cell. Following are some of the machines & devices that aid in speedy production of our gamut:

Fabrication Shop Machinery

Air Compressor

MMAW Welding Machine

DISH Forming Hydraulic Press of 3000 MM DIA X 500 MT Capacity (Future)

Plasma Cutting Machine up to 30 MM Thk Plate

EOT Crane of 10.0 MT Capacity (Future)

PLATE Bending Machine of 3000 MM wide X 20 MM Capacity (Future)

EOT Crane of 5.0MT Capacity

Portable Gas Cutting Set

Grinding, Polishing & Buffing Equipments

Profile - Sap Cutting Machine Dedicated for MS /SS Plate Cutting

Heating Own for Welding Rod

PUG Cutting Machine Dedicated for MS / SS Plate Cutting

JIB Crane (Future)

Testing Equipments

Lifting & Shifting Devices

TIG Welding Machine

Magnetic & Portable Drill Machine

X-Ray Film Viewer for Radiography

Measuring Instruments & Tools

MIG Welding Machine

Machine Shop: Future

Lathe Machine

Radial Drill Machine

Sapping Machine


In addition, our production cell includes:

Details

Make

Qty.

Bending Machines (Future)

Size:3.0 MT.WIDE X 20 MM Thk

01

Shearing Machines

Manual

01

Plasma cutting Machines

Electro Plasma

02

Radial drilling Machines

Cap :60 MM

01

Welding Machines

ADOR : Arc /Argon / MIG

07

Plate Bending & Dishing Machines (Future)

External / Planning for Plate Bending Wide:3.0 M X 20 MM THK, Dishing Press Cap: 500 MT: Size: 3.0 M Dia.

01

Lathe Machines (Proposed)

Bed Length

Max Shaft Dia.

Accuracy

No

6 ft / 12 ft

Up to 450 MM Diameter

0.00