Quality Control

Quality Assurance

Excellence in Every Step
At NCP Africa, we are committed to upholding the highest quality standards, and our operations adhere to ISO 9001 principles. Our dedication to quality assurance is evident in our meticulous processes and stringent inspections throughout every stage of your project.

 

Our Quality Assurance Measures Include:

NDT (Non-Destructive Testing): All NDT processes are conducted by independent, South Africa-based NDT technicians at pre-determined Hold Points.
Hold Points Inspection: Our NCP Africa Project Engineers and QA Designates meticulously inspect all Hold Points. These include examinations of:

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Casting Processes:

  • NDT
  • Fettling
  • Workpiece Set Up
  • Final Machining
  • Gear Cutting
  • Work-piece Run Outs
  • Dimensional Inspections
  • FAT (Factory Acceptance Testing)
  • Sandblasting
  • Painting
  • Packaging
Vendor Data Report Management:

Our comprehensive document control management ensures the accuracy and integrity of Vendor Data Reports.

QCP (Quality Control Plans):

We establish detailed Quality Control Plans for every component we manufacture, ensuring consistent quality standards.

Full Manufacturing Data Report (MDR):

Upon project completion, we issue a comprehensive Manufacturing Data Report (MDR) that provides a complete record of the manufacturing process, certifying the quality and compliance of your project.

At NCP Africa, quality assurance is not just a process; it’s our commitment to delivering excellence in every aspect of your project. Trust us to uphold the highest standards and provide you with exceptional results. Your satisfaction is our ultimate goal.

Design and Expertise

Process Design

Precision in Mill Sizing and Beyond

At NCP Africa, our process design is the bedrock of mill efficiency and performance. We bring a wealth of knowledge and cutting-edge methods to ensure your mill processes are optimized for success.

Key Elements of Our Process Design:

Mill Sizing: Utilizing modified Bond Theory with established Service Factors derived from our extensive practical experience for Ball Mill sizing.

SAG/AG mills are sized using a hybrid model, incorporating published data from industry experts like Barrett, Austen & Morrell.

Development of a Specific Energy / Breakage distribution model for precise SAG Mill sizing.

Process-Design
Comprehensive Details:

Our model goes beyond standard sizing and offers detailed insights such as PFDs (Process Flow Diagrams), PSDs (Particle Size Distributions), Mass Balances, Stream Products, and particle size distribution predictions.

Covers the entire comminution plant, including screening, milling, and classification.

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Mechanical Design

Structural Integrity and Efficiency

At NCP Africa, our mechanical design expertise ensures the structural integrity and operational efficiency of your mill.

Key Aspects of Our Mechanical Design:

Finite Element Analysis (FEA):

Employed with a 3-dimensional Structural Finite Element package.

Integrated into our 3D Modeling Package for comprehensive analysis.

Design Standards:

Mill structures designed in compliance with AAC323001 standards.
Incorporation of Casting Simulations, Fatigue Analysis (in line with BS7608), and Fluid Film Analysis.
Gearbox designs undergo review according to AGMA 2001:C95, with specified Service Factors (SF) ranging between 2.0 and 2.3.

Bearing and Coupling Life:

  • Bearing life specifications: L10 basic 52,000 hours.
  • Pinion Bearing life: L10h ≥ 100,000 hours.
  • NCPI specifications mandate Couplings SF > 2.0.
Gearing Excellence:

  • Open Gearing designs align with AGMA 321.05 / 6014:B15 standards.
  • Strength > 2.50 and Durability between 1.5 and 1.75.

Electrical, Instrumentation & Control (E&I) Design

Seamless Integration for Optimal Control

Our E&I design ensures the seamless operation and control of your mill processes, guaranteeing efficiency and reliability.

Key Aspects of Our E&I Design:

  • Specialist Subcontractors: Management of VSD (Variable Speed Drive) Specialist Subcontractors, Comprehensive review and management of Main Drive Motor Design.
  • Induced Torque Spike: Rigorous design review to address induced torque spikes.
  • PLC Implementation: PLC (Programmable Logic Controller) design and implementation for precise control.
  • E&I Interface: Effective management of Electrical, Instrumentation & Control System interfaces for a harmonious operation.
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At NCP Africa, we integrate precision into every aspect of your mill design, from process optimization to mechanical integrity and control systems. Partner with us for excellence in mill engineering and design.