Inspection and Testing

1. MEGA Kontrol Production Inspections

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a. Pre-Production Inspection and material entry quality controls (PPI, Pre-Production Insection) 

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Pre-production inspections constitute one of the cornerstones of risk assessment and quality assurance management. Pre-production inspection is the most effective way to verify that your supplier can start production, meet your specifications, or adhere to your quality requirements.

We inspect the main raw materials and semi-finished products of the products you supply from your suppliers, natural gas and oil pipeline equipment (such as valves, pipes, fittings, etc.) before starting production. We approve the production of products by performing tests and controls according to ITP, which is approved as sampling or 100%. In this way, we determine the risks you may encounter in your projects in advance and ensure that precautions are taken.

During this inspection, MEGA Kontrol expert auditor prepared the checklist and approved Inspection & According to the Test Plan (ITP);

• Verifies availability and condition of materials / raw materials / semi-finished products,

• Reviews the manufacturer's production preparation and planning,

• Controls the manufacturer's machinery and equipment park,

• Performs the necessary destructive or non-destructive tests on the products according to ITP,

• Performs dimensional and visual checks,

• Supervises the supplier's/manufacturer's in-house quality control,

• It helps prepare for future product reviews.

Our pre-production inspections can be performed at your supplier and/or company just before production begins or before final assembly begins. A PPI allows you to earn:

• Clear understanding of production schedules,

• Ability to measure your manufacturer's ability to meet your needs and quality targets,

• Ability to detect potential problems that may affect project schedule or product quality,

• Assurance that your needs will be met,

• Assurance about the quality of raw materials and semi-finished products and product components.

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b. Controls and Inspections During Production, (DPI or DUPRO - During Production)

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During production controls and inspection (DPI), also known as DUPRO, is a quality control inspection performed while production is ongoing. These quality control inspections are carried out when the production of the products continues and between 10% and 60% of the production is completed. During this inspection, we identify production deviations and provide feedback on corrective measures. We recheck these corrective actions during our pre-shipment inspections to verify that they have been corrected.

At each stage of the production process, MEGA Control expert inspectors will prepare a detailed inspection report with supporting photographs to give you a comprehensive overview and give you all the information and data you need.

 

Some of the benefits that controls and inspection (DPI) during production, also known as DUPRO, will provide you can be listed as follows;

• It allows you to confirm that quality and compliance with specifications/standards are maintained throughout the production process.

• If there are any problems that need to be fixed, it allows them to be detected early.

• It contributes to the timely delivery of your projects.

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c. Initial Production / Product Controls (IPC, Initial Production Control)

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Initial Production Control (IPC) is an on-site Product Inspection performed on manufactured products and inspection of raw materials and components. Preliminary inspection of all machinery, equipment and materials to be used in production is carried out, and quality controls, dimensional controls and visual inspections of the first products produced are carried out in accordance with the relevant ITP. Initial Production Control (IPC) is the first step in ensuring the quality of your product is consistent throughout production and is an early warning system that protects your product against costly import risks.

MEGA Control uses the internationally accepted standard ANSI/ASQC Z1.4 (ISO 2859-1) statistical sampling standard for Initial Production Control (IPC).

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D. Factory Acceptance Tests and Audits (FAT)

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Factory Acceptance Test (FAT)It is a process that evaluates equipment/product during and/or after the assembly process, verifying that it is manufactured and operates in accordance with design specifications. As the name suggests, these tests are carried out at the manufacturer's factory.

Factory Acceptance Testing (FAT) is generally performed to evaluate any problems, inconsistencies and nonconformities and develop a process for how to address them. Deviations or nonconformities observed during testing are documented in an inspection report and corrected before shipment.

 

During the Factory Acceptance Test (FAT), your products are checked against the specifications and standards listed below.Inspection & Test Plan (ITP) We do it accordingly and report it in an inspection report with detailed photographs.

• API 6D Valves Factory Acceptance Tests,

• API 6A Wellhead & Tree Equipment Factory Acceptance Tests,

• RMS-A, RMS-B and RMS-C Factory Acceptance Tests,

• Valve Groups produced according to Botaş specifications's Factory Acceptance Tests,

• API 5L Pipes's Factory Acceptance Tests,

• Factory Acceptance Tests of API 16A Drill Through Equipment,

• API 602Gate, Globe and Check Valvesn Factory Acceptance Tests,

• API 600 Gate Valves Factory Acceptance Tests,

• Factory Acceptance Tests of Various Pressure Equipment,

• TS ISO17292 and ISO 14141 Tests,

• TS 9809, TS EN 331, TS EN 1983, TS 3148 Tests,

• API 598 Tests,

 

In parallel or in addition to these standards and specifications, the following tests can be carried out in accordance with ITP;

• Functional tests,

• Pressure Tests,

• Hydrostatic Shell and Seat Tests,

• Pneumatic Tests,

• Antistatic Tests,

• Torque Tests,

• Hardness Measurements,

• Thickness Measurements,

• Dimensional and visual controls,

• NDE non-destructive inspection report controls,

• Documentation checks

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E. Pre-Shipment Inspection (PSI)

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Pre-shipment inspection (PSI) is a systematic inspection of randomly selected products or all products (at 100%) from all batches of your order when at least 80% of your production is complete or ready for shipment. This is your last opportunity to take corrective action before your production is finished and packaged. PSI becomes an effective tool to protect your Product against costly import risks. MEGA Kontrol Inspection Before Shipment (PSI) uses the internationally accepted standard ANSI/ASQC Z1.4 (ISO 2859-1) statistical sampling standard.

A Pre-Shipment Inspection (PSI) by MEGA Kontrol provides you with a guarantee that your products have been successfully completed before they are shipped by the manufacturer. The globalized market of our time offers many opportunities but also poses great risks. When working with an overseas supplier, it is crucial to ensure that the specifications you agreed upon are actually met.

 

We can list some of the benefits we provide with MEGA Kontrol pre-shipment inspection (PSI) as follows;

• By taking the necessary precautions, you will reduce the risk of incorrectly fulfilled orders.

• You will be assured that your order has been fulfilled correctly before it departs.

• You get quality controlled at the center and you don't have to pay for problematic products,

• You ensure that the supplier or manufacturer meets all agreed upon specifications.

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2. Supplier Audit Services

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Supplier audits evaluate your potential suppliers according to certain internationally accepted standards.(API Q1, ISO 9001, API 6D, API 6A, API 5L, ISO 16949 etc. like) It is a special inspection that we carry out. Your suppliers who have passed supplier audits are suppliers with strong quality management systems according to industry standards. Additionally, to ensure that your suppliers can consistently supply high quality materials/products and services throughout your business partnership.MEGA Kontrol Supplier InspectionsI It would be a very right step.

 

MEGA Control Supplier audits cover all legal aspects of a supplier, its compliance with relevant standards and specifications, as well as functional aspects of the supplier. This gives you confidence when working with these suppliers.

 

Here are a few advantages you will benefit from MEGA Kontrol Supplier audits:

• Guarantee of working with suppliers who will provide the highest quality products and/or services,

• Ensuring that your supplier operates in accordance with your management systems and/or specifications, thus ensuring traceability,

• Avoiding illegal and counterfeit suppliers that produce counterfeit products,

• Determining the capacity of suppliers to make your production plans more efficient,

• Ensuring a smooth supply chain,

• Gain customer satisfaction,

• To follow the performance of your suppliers and plan your production processes accordingly.

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By selecting highly trained auditors for MEGA Kontrol supplier audits, the supplier company is checked in many aspects, including;

• Quality / environment / OHS management system certificates of the supplier company,

• Personnel qualification of the supplier company, personnel certificates and training records showing the ability and competence of the relevant personnel,

• Examining the supplier company's facility in terms of capacity in storage, production, transportation and other similar aspects,

• Controls of procedures and processes,

• Documentation checks,

• Company identification and traceability controls,

• The role and functionality of the quality assurance department,

• Quality control capacity and activity, Controlling calibration activities,

• Machinery and equipment park, maintenance and control of records.

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3. Testing and Analysis

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In the ever-growing international market, companies work to ensure that their products meet the expectations of their consumers in terms of both safety and quality and comply with relevant standards and specifications. Testing and analysis are an important part of establishing and managing a strong supply chain and ensuring that products comply with applicable standards.

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Our Quality Control unit and its capabilities;

1. Chemical Analysis Test with Spectrometer

2. PMI (Positive Material Identification) Test

3. Tensile – Tensile Test

4. Charpy Test

5. Bending Test

6. Micro Analysis

7. Macro Analysis

8. Metallic Hardness Measurement

9. Non-metallic Hardness Measurement

10. Dimensional Controls

11. Wall Thickness Measurement Tests

12. NDE – VT - Visual Inspections

13. NDE – MT - Magnetic Test

14. NDE – PT – Penetrant Test

15. NDE – UT – Ultrasonic Test

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4. Management Systems Audit Services (MSA – Management Systems Audit)

 

We audit your company according to the management systems listed below and strengthen the power of your product, service and management systems. We provide detailed reports after all inspections and enable you to see possible malfunctions and problems and take precautions.

 

• ISO 9001:2015 Quality Management System Audit

• ISO 14001:2015 Environmental Management System Audit

• ISO 45001:2018 OHS Management System Audit

• API Q1 Quality Management System Audit

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5. Protective Coating and Paint Inspections (PCI - Protective Coating Inspection)

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The coating and paint quality of the surfaces is an important factor for long-term use of the products and reducing maintenance costs.

• In natural gas and oil pipelines,

• At RMS-A, RMS-B, RMS-C stations,

• natural gas and oil pipeline valves, pipes and all other equipment and

• We provide control services for protective coating and painting processes of other industrial products according to international standards, customer requirements or specifications.

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Paint Control Tests;

1. Cross-Cut Test

2. Adhesion Test

3. Abrasive Testing

4. Pure Test

5. Surface Dust

6. Compressed Air Cleanliness Control

7. Roughness / Surface Profile

8. Residual Salt Contamination

9. Paint Thickness Measurement

10. Paint Visual Checks