Page 1 of 12

REPORT ON

ROOT CAUSE ANALYSIS amp CORRECTIVE ACTION FOR

SEAT LEAKAGE

Team Members

D Muralidharan ndash DGM Production

MK Baranidharan ndash DGM Quality control

KAnand ndash Manager Production

RKrishnaprasad-Manger Painting and Packing

P Jayaraman ndash Executive Quality Assurance

Raja Chacko ndash Manager Quality control

KPradeep ndash Executive Quality control

Date 16-Sept -2014

Ref Communication from GASCO on 10092014

Page 2 of 12

CONTENTS

10 Problem description

20 Background

30 Preliminary Analysis

40 Correction

50 Root cause Analysis

60 Verification

70 Corrective action

Page 3 of 12

10 Problem description

It was reported from Gasco - Habshan Direct Depressurization Project site that

following valve are seat passing during hydro testing

DESCON ENGINEERING ABU DHABI HABSHAN DIRECT DEPRESSURIZATION-1 (HDD-1)

VALVES MONITORING SHEET TESTING

Sr No

Tag No

Valve Type

Size ()

Rating Heat No Sl No Test Date

Hydro test Pneumatic Test

Test Status

Back Seat

Shell Side

Seat test 1

Seat Test 2

Seat test 1

Seat Test 2

1 VC-006 Check Valve

2 150 3H164 13902796 8-Sep-14 NA OK FAIL - - - Fail

2 VC-006 Check Valve

2 150 3H164 13902797 8-Sep-14 NA OK FAIL - - - Fail

3 VC-006 Check Valve

2 150 3H164 13902798 8-Sep-14 NA OK FAIL - - - Fail

4 VG-003 Gate Valve

2 300 N3444 13902240 9-Sep-14 OK OK FAIL - - - Fail

Page 4 of 12

20 Background

3 valves of 2rdquo150 WCB Check valve amp 1 valve of 2rdquo300 WCB Gate supplied to Gasco - Habshan Direct

Depressurization on account of NAMA Mott was seat passing

Customer GASCO GASCO

Valve Type Check Gate

Valve size 2rdquo 2rdquo

Class 150 300

Material WCB LCB

Quantity 3 Nos

1 No

Main valve serial no 13902796 1390279713902798

13902240

Tag number VC-006 VG-003

Customer PO NMMP302901PO007 REV 2

NMMP302901PO007 REV 2

LampT Valves Sale Order Line item No

12000008120 800010410

30 Preliminary Analysis

Valve serial no 13902796 1390279713902798 13902240

Heat no 3H164 N3444

Foundry Auto Shell Cast Pvt Ltd Veeyes foundry

RT no LIR2602 LIR2603 LIR2601 VR1798

Test report verified verified

Page 5 of 12

We have verified the following the manufacturing documents

1) Test certificate verified

2) The above valves were tested internally by LampT Valves and offered to Third Party Inspection

agencies - RGopalasamy (NMM) amp KGopinath (Intertek) Valve test report verified and found

acceptable

3) All marking details were verified as per GADcustomer PO requirement

4) On completion of Pressure testing Valves were cleared and applied rust preventive and final

inspection done by QC and moved to grit blasting amp painting

5) Painting amp packing witnessed by approved TPI agency (inspected report enclosed)

6) Before dispatch (PDI) inspection carried out amp cleared Refer below photos

VTC - report

Page 6 of 12

40 Correction

It was reported that foreign particle may present inside the seat surfaces which leads to seat leakage in the valves

50 Root Cause Analysis

RCA - ROOT CAUSE ANALYSIS SHEET ndash GLAND LEAKAGE PROBLEM DESCRIPTION DESCRIPTION AREA DESCRIPTION DATA

WHAT

Seat leakage noticed Leakage was noticed during testing at site

WHERE Leak noticed in seat surfaces Leak noticed in disc amp seat ring seating surfaces

WHEN

pressure testing at site Leak noticed during pressure testing at required seat pressure

HOW BIG Visible leak found Leakage found in valve closed condition

Similar Parts Gate valve ndash 1 no Gate valve of 2rdquo300 class observed seat leak

Page 7 of 12

S No CAUSES SIGNIFICANT IN-

SIGNIFICANT

1 Improper masking with end cover while preparation of surfaces amp improper sealing of flow bores with end cover after completing of painting inspection

may cause foreign particle to enter

significant

2 Improper surface contact between the seat surfaces Insignificant

3 Rust preventive Gel brush contaminated by foreign particle Insignificant

4 In adequate surface finish between the seating surfaces Insignificant

5 Positioning amp locating the valve for surface preparation Insignificant

6 Improper cleaning at intrinsic areas Insignificant

7 Lack of awareness significant

8 Difference in hardness was not maintained Insignificant

CAUSE AND EFFECT DIAGRAM - DEFINE amp VERIFY ROOT CAUSE

MAN MATERIALS

METHODSPROCESSES MACHINE

PROBLEM

STATEMENT

Visible Seat

leakage at site

Improper masking improper sealing

with end cover

Improper cleaning at

intrinsic areas

Lack of Awareness amp

training

Difference in hardness was not

maintained

Improper surface contact

between the seat surfaces

In adequate surface finish between the

seating surfaces

Rust preventive gel brush

contaminated by foreign

particles

Positioning amp locating the valve for

surface preparation

Page 8 of 12

60 Verification

S No CAUSES Verification status

1 Improper masking

improper sealing

Valve to be properly masked during surface preparation amp to seal the ends

with end protector

2 Improper surface

contact

Contact surfaces were checked with blue matching were verified during

assembly stage

3 Contamination of RP Gel

brush

Clean amp dust free materials were used for applying the rust preventive

gels and follows the procedure

4 In adequate surface

finish

Surface finish was checked during assembly and follows as per procedure

5 Positioning amp locating Positioning amp locating the valves were checked and follows the procedure

for surface preparation

6 Improper cleaning at

intrinsic areas

Post cleaning was done after surface preparation and painting inspection

were carried out and found acceptable

7 Lack of awareness amp

training

Critical areas to check amp awareness on procedure to be followed before

packing the valves

8 Difference in hardness

was not maintained

Seating surface materials were found acceptable with required hardness

as per procedure

Page 9 of 12

70 Corrective action

Based on the above the following corrective actions are suggested

1 Additional care has been taken to avoid entering of foreign particles during grit blasting painting amp packing A separate SOP to be released on Grit blast masking

2 Photograph will be taken for each valve to ensure the cleanliness of internals after applying gel and same will be ensured during packing amp pre dispatch inspection

80 Action plan on Corrective Action 1 Significant cause for the complaint has been discussed with the Grit blasting and painting team

2 Training and awareness in standard operating procedure given for QC Grit blasting and painting

team

3 A separate SOP has been released on Grit blast masking (Refer attached)

Page 10 of 12

4 Training given on masking locations to the grit blasting team

5 Masking of body amp bonnet cover joints amp flow bore areas were done with readymade plaster masks Self-adhesive masking tapes for both raised face and Butt weld ends

6 Masking of stuffing box areas amp gear unit locations were done with good dense wax before preparing the surfaces through grit blasting

Page 11 of 12

7 Below images shows the rigidity of masking to restrict the entrance of foreign particles into the flow bore Masking done before blasting remains damage free even after completion of painting

8 End capprotector used after completion of painting application of rust preventive Gel and after QC inspection Same will be ensured during pre-Dispatch inspection

9 Training has been given to the concerns amp additional check has been made to ensure internals are free from foreign particles and recorded in a report(attached below)

Page 12 of 12

Enclosure

1) Test certificate

2) Valve test report

3) Painting inspection report

4) Packing inspection report

5) Training attendance sheet

6) Visual inspection report

Prepared by Approved by

KPradeep Raja C

Date 27102014

== End of report ==

LEtT VALVESLIMITED AUDIT CHECK INSPECTION REPORT REPORT ACO 1 0

Locatfon W2C Date 220914

Stage of Inspection Masked va(ve[ reg Blastingl Primer J Time 300PM

Procedure Ref PPSG-11ril DT 180914 Spec free of foreign particle

Item Description Masked valve [6cass6QO Gate-14G201033] after de~masking

Test Type Method I Acceptance middotmiddotmiddotmiddotmiddot1 Result I Remarks i ~~~~__~~ln~st~r~um~en~t~~~cn~middott~e~rt7middot~~~~~~~~__+70-===~~~__-------~IMasking Visual 1] No damage in masking tape 1Proper maskingmiddot Passed

effeciveness Inspection 2] Covered aU relevant areas I-wi~tgne=ss~ed~=-==-__-+-i inspection as per 3) No grit entry in to flow bore 2No damages -ensured Procedure 4J No metal damges on 3Masking practice comply

U Photographs serrationfr stem threads due to to the Procedure I a I blasting requirement i~checklist__-____________________--L

TESTED BY VERIFIED BY

A-~ tgto~ A VeWlIgiri QA PJayaramanl(Ji

Page 2 of 12

CONTENTS

10 Problem description

20 Background

30 Preliminary Analysis

40 Correction

50 Root cause Analysis

60 Verification

70 Corrective action

Page 3 of 12

10 Problem description

It was reported from Gasco - Habshan Direct Depressurization Project site that

following valve are seat passing during hydro testing

DESCON ENGINEERING ABU DHABI HABSHAN DIRECT DEPRESSURIZATION-1 (HDD-1)

VALVES MONITORING SHEET TESTING

Sr No

Tag No

Valve Type

Size ()

Rating Heat No Sl No Test Date

Hydro test Pneumatic Test

Test Status

Back Seat

Shell Side

Seat test 1

Seat Test 2

Seat test 1

Seat Test 2

1 VC-006 Check Valve

2 150 3H164 13902796 8-Sep-14 NA OK FAIL - - - Fail

2 VC-006 Check Valve

2 150 3H164 13902797 8-Sep-14 NA OK FAIL - - - Fail

3 VC-006 Check Valve

2 150 3H164 13902798 8-Sep-14 NA OK FAIL - - - Fail

4 VG-003 Gate Valve

2 300 N3444 13902240 9-Sep-14 OK OK FAIL - - - Fail

Page 4 of 12

20 Background

3 valves of 2rdquo150 WCB Check valve amp 1 valve of 2rdquo300 WCB Gate supplied to Gasco - Habshan Direct

Depressurization on account of NAMA Mott was seat passing

Customer GASCO GASCO

Valve Type Check Gate

Valve size 2rdquo 2rdquo

Class 150 300

Material WCB LCB

Quantity 3 Nos

1 No

Main valve serial no 13902796 1390279713902798

13902240

Tag number VC-006 VG-003

Customer PO NMMP302901PO007 REV 2

NMMP302901PO007 REV 2

LampT Valves Sale Order Line item No

12000008120 800010410

30 Preliminary Analysis

Valve serial no 13902796 1390279713902798 13902240

Heat no 3H164 N3444

Foundry Auto Shell Cast Pvt Ltd Veeyes foundry

RT no LIR2602 LIR2603 LIR2601 VR1798

Test report verified verified

Page 5 of 12

We have verified the following the manufacturing documents

1) Test certificate verified

2) The above valves were tested internally by LampT Valves and offered to Third Party Inspection

agencies - RGopalasamy (NMM) amp KGopinath (Intertek) Valve test report verified and found

acceptable

3) All marking details were verified as per GADcustomer PO requirement

4) On completion of Pressure testing Valves were cleared and applied rust preventive and final

inspection done by QC and moved to grit blasting amp painting

5) Painting amp packing witnessed by approved TPI agency (inspected report enclosed)

6) Before dispatch (PDI) inspection carried out amp cleared Refer below photos

VTC - report

Page 6 of 12

40 Correction

It was reported that foreign particle may present inside the seat surfaces which leads to seat leakage in the valves

50 Root Cause Analysis

RCA - ROOT CAUSE ANALYSIS SHEET ndash GLAND LEAKAGE PROBLEM DESCRIPTION DESCRIPTION AREA DESCRIPTION DATA

WHAT

Seat leakage noticed Leakage was noticed during testing at site

WHERE Leak noticed in seat surfaces Leak noticed in disc amp seat ring seating surfaces

WHEN

pressure testing at site Leak noticed during pressure testing at required seat pressure

HOW BIG Visible leak found Leakage found in valve closed condition

Similar Parts Gate valve ndash 1 no Gate valve of 2rdquo300 class observed seat leak

Page 7 of 12

S No CAUSES SIGNIFICANT IN-

SIGNIFICANT

1 Improper masking with end cover while preparation of surfaces amp improper sealing of flow bores with end cover after completing of painting inspection

may cause foreign particle to enter

significant

2 Improper surface contact between the seat surfaces Insignificant

3 Rust preventive Gel brush contaminated by foreign particle Insignificant

4 In adequate surface finish between the seating surfaces Insignificant

5 Positioning amp locating the valve for surface preparation Insignificant

6 Improper cleaning at intrinsic areas Insignificant

7 Lack of awareness significant

8 Difference in hardness was not maintained Insignificant

CAUSE AND EFFECT DIAGRAM - DEFINE amp VERIFY ROOT CAUSE

MAN MATERIALS

METHODSPROCESSES MACHINE

PROBLEM

STATEMENT

Visible Seat

leakage at site

Improper masking improper sealing

with end cover

Improper cleaning at

intrinsic areas

Lack of Awareness amp

training

Difference in hardness was not

maintained

Improper surface contact

between the seat surfaces

In adequate surface finish between the

seating surfaces

Rust preventive gel brush

contaminated by foreign

particles

Positioning amp locating the valve for

surface preparation

Page 8 of 12

60 Verification

S No CAUSES Verification status

1 Improper masking

improper sealing

Valve to be properly masked during surface preparation amp to seal the ends

with end protector

2 Improper surface

contact

Contact surfaces were checked with blue matching were verified during

assembly stage

3 Contamination of RP Gel

brush

Clean amp dust free materials were used for applying the rust preventive

gels and follows the procedure

4 In adequate surface

finish

Surface finish was checked during assembly and follows as per procedure

5 Positioning amp locating Positioning amp locating the valves were checked and follows the procedure

for surface preparation

6 Improper cleaning at

intrinsic areas

Post cleaning was done after surface preparation and painting inspection

were carried out and found acceptable

7 Lack of awareness amp

training

Critical areas to check amp awareness on procedure to be followed before

packing the valves

8 Difference in hardness

was not maintained

Seating surface materials were found acceptable with required hardness

as per procedure

Page 9 of 12

70 Corrective action

Based on the above the following corrective actions are suggested

1 Additional care has been taken to avoid entering of foreign particles during grit blasting painting amp packing A separate SOP to be released on Grit blast masking

2 Photograph will be taken for each valve to ensure the cleanliness of internals after applying gel and same will be ensured during packing amp pre dispatch inspection

80 Action plan on Corrective Action 1 Significant cause for the complaint has been discussed with the Grit blasting and painting team

2 Training and awareness in standard operating procedure given for QC Grit blasting and painting

team

3 A separate SOP has been released on Grit blast masking (Refer attached)

Page 10 of 12

4 Training given on masking locations to the grit blasting team

5 Masking of body amp bonnet cover joints amp flow bore areas were done with readymade plaster masks Self-adhesive masking tapes for both raised face and Butt weld ends

6 Masking of stuffing box areas amp gear unit locations were done with good dense wax before preparing the surfaces through grit blasting

Page 11 of 12

7 Below images shows the rigidity of masking to restrict the entrance of foreign particles into the flow bore Masking done before blasting remains damage free even after completion of painting

8 End capprotector used after completion of painting application of rust preventive Gel and after QC inspection Same will be ensured during pre-Dispatch inspection

9 Training has been given to the concerns amp additional check has been made to ensure internals are free from foreign particles and recorded in a report(attached below)

Page 12 of 12

Enclosure

1) Test certificate

2) Valve test report

3) Painting inspection report

4) Packing inspection report

5) Training attendance sheet

6) Visual inspection report

Prepared by Approved by

KPradeep Raja C

Date 27102014

== End of report ==

LEtT VALVESLIMITED AUDIT CHECK INSPECTION REPORT REPORT ACO 1 0

Locatfon W2C Date 220914

Stage of Inspection Masked va(ve[ reg Blastingl Primer J Time 300PM

Procedure Ref PPSG-11ril DT 180914 Spec free of foreign particle

Item Description Masked valve [6cass6QO Gate-14G201033] after de~masking

Test Type Method I Acceptance middotmiddotmiddotmiddotmiddot1 Result I Remarks i ~~~~__~~ln~st~r~um~en~t~~~cn~middott~e~rt7middot~~~~~~~~__+70-===~~~__-------~IMasking Visual 1] No damage in masking tape 1Proper maskingmiddot Passed

effeciveness Inspection 2] Covered aU relevant areas I-wi~tgne=ss~ed~=-==-__-+-i inspection as per 3) No grit entry in to flow bore 2No damages -ensured Procedure 4J No metal damges on 3Masking practice comply

U Photographs serrationfr stem threads due to to the Procedure I a I blasting requirement i~checklist__-____________________--L

TESTED BY VERIFIED BY

A-~ tgto~ A VeWlIgiri QA PJayaramanl(Ji

Page 3 of 12

10 Problem description

It was reported from Gasco - Habshan Direct Depressurization Project site that

following valve are seat passing during hydro testing

DESCON ENGINEERING ABU DHABI HABSHAN DIRECT DEPRESSURIZATION-1 (HDD-1)

VALVES MONITORING SHEET TESTING

Sr No

Tag No

Valve Type

Size ()

Rating Heat No Sl No Test Date

Hydro test Pneumatic Test

Test Status

Back Seat

Shell Side

Seat test 1

Seat Test 2

Seat test 1

Seat Test 2

1 VC-006 Check Valve

2 150 3H164 13902796 8-Sep-14 NA OK FAIL - - - Fail

2 VC-006 Check Valve

2 150 3H164 13902797 8-Sep-14 NA OK FAIL - - - Fail

3 VC-006 Check Valve

2 150 3H164 13902798 8-Sep-14 NA OK FAIL - - - Fail

4 VG-003 Gate Valve

2 300 N3444 13902240 9-Sep-14 OK OK FAIL - - - Fail

Page 4 of 12

20 Background

3 valves of 2rdquo150 WCB Check valve amp 1 valve of 2rdquo300 WCB Gate supplied to Gasco - Habshan Direct

Depressurization on account of NAMA Mott was seat passing

Customer GASCO GASCO

Valve Type Check Gate

Valve size 2rdquo 2rdquo

Class 150 300

Material WCB LCB

Quantity 3 Nos

1 No

Main valve serial no 13902796 1390279713902798

13902240

Tag number VC-006 VG-003

Customer PO NMMP302901PO007 REV 2

NMMP302901PO007 REV 2

LampT Valves Sale Order Line item No

12000008120 800010410

30 Preliminary Analysis

Valve serial no 13902796 1390279713902798 13902240

Heat no 3H164 N3444

Foundry Auto Shell Cast Pvt Ltd Veeyes foundry

RT no LIR2602 LIR2603 LIR2601 VR1798

Test report verified verified

Page 5 of 12

We have verified the following the manufacturing documents

1) Test certificate verified

2) The above valves were tested internally by LampT Valves and offered to Third Party Inspection

agencies - RGopalasamy (NMM) amp KGopinath (Intertek) Valve test report verified and found

acceptable

3) All marking details were verified as per GADcustomer PO requirement

4) On completion of Pressure testing Valves were cleared and applied rust preventive and final

inspection done by QC and moved to grit blasting amp painting

5) Painting amp packing witnessed by approved TPI agency (inspected report enclosed)

6) Before dispatch (PDI) inspection carried out amp cleared Refer below photos

VTC - report

Page 6 of 12

40 Correction

It was reported that foreign particle may present inside the seat surfaces which leads to seat leakage in the valves

50 Root Cause Analysis

RCA - ROOT CAUSE ANALYSIS SHEET ndash GLAND LEAKAGE PROBLEM DESCRIPTION DESCRIPTION AREA DESCRIPTION DATA

WHAT

Seat leakage noticed Leakage was noticed during testing at site

WHERE Leak noticed in seat surfaces Leak noticed in disc amp seat ring seating surfaces

WHEN

pressure testing at site Leak noticed during pressure testing at required seat pressure

HOW BIG Visible leak found Leakage found in valve closed condition

Similar Parts Gate valve ndash 1 no Gate valve of 2rdquo300 class observed seat leak

Page 7 of 12

S No CAUSES SIGNIFICANT IN-

SIGNIFICANT

1 Improper masking with end cover while preparation of surfaces amp improper sealing of flow bores with end cover after completing of painting inspection

may cause foreign particle to enter

significant

2 Improper surface contact between the seat surfaces Insignificant

3 Rust preventive Gel brush contaminated by foreign particle Insignificant

4 In adequate surface finish between the seating surfaces Insignificant

5 Positioning amp locating the valve for surface preparation Insignificant

6 Improper cleaning at intrinsic areas Insignificant

7 Lack of awareness significant

8 Difference in hardness was not maintained Insignificant

CAUSE AND EFFECT DIAGRAM - DEFINE amp VERIFY ROOT CAUSE

MAN MATERIALS

METHODSPROCESSES MACHINE

PROBLEM

STATEMENT

Visible Seat

leakage at site

Improper masking improper sealing

with end cover

Improper cleaning at

intrinsic areas

Lack of Awareness amp

training

Difference in hardness was not

maintained

Improper surface contact

between the seat surfaces

In adequate surface finish between the

seating surfaces

Rust preventive gel brush

contaminated by foreign

particles

Positioning amp locating the valve for

surface preparation

Page 8 of 12

60 Verification

S No CAUSES Verification status

1 Improper masking

improper sealing

Valve to be properly masked during surface preparation amp to seal the ends

with end protector

2 Improper surface

contact

Contact surfaces were checked with blue matching were verified during

assembly stage

3 Contamination of RP Gel

brush

Clean amp dust free materials were used for applying the rust preventive

gels and follows the procedure

4 In adequate surface

finish

Surface finish was checked during assembly and follows as per procedure

5 Positioning amp locating Positioning amp locating the valves were checked and follows the procedure

for surface preparation

6 Improper cleaning at

intrinsic areas

Post cleaning was done after surface preparation and painting inspection

were carried out and found acceptable

7 Lack of awareness amp

training

Critical areas to check amp awareness on procedure to be followed before

packing the valves

8 Difference in hardness

was not maintained

Seating surface materials were found acceptable with required hardness

as per procedure

Page 9 of 12

70 Corrective action

Based on the above the following corrective actions are suggested

1 Additional care has been taken to avoid entering of foreign particles during grit blasting painting amp packing A separate SOP to be released on Grit blast masking

2 Photograph will be taken for each valve to ensure the cleanliness of internals after applying gel and same will be ensured during packing amp pre dispatch inspection

80 Action plan on Corrective Action 1 Significant cause for the complaint has been discussed with the Grit blasting and painting team

2 Training and awareness in standard operating procedure given for QC Grit blasting and painting

team

3 A separate SOP has been released on Grit blast masking (Refer attached)

Page 10 of 12

4 Training given on masking locations to the grit blasting team

5 Masking of body amp bonnet cover joints amp flow bore areas were done with readymade plaster masks Self-adhesive masking tapes for both raised face and Butt weld ends

6 Masking of stuffing box areas amp gear unit locations were done with good dense wax before preparing the surfaces through grit blasting

Page 11 of 12

7 Below images shows the rigidity of masking to restrict the entrance of foreign particles into the flow bore Masking done before blasting remains damage free even after completion of painting

8 End capprotector used after completion of painting application of rust preventive Gel and after QC inspection Same will be ensured during pre-Dispatch inspection

9 Training has been given to the concerns amp additional check has been made to ensure internals are free from foreign particles and recorded in a report(attached below)

Page 12 of 12

Enclosure

1) Test certificate

2) Valve test report

3) Painting inspection report

4) Packing inspection report

5) Training attendance sheet

6) Visual inspection report

Prepared by Approved by

KPradeep Raja C

Date 27102014

== End of report ==

LEtT VALVESLIMITED AUDIT CHECK INSPECTION REPORT REPORT ACO 1 0

Locatfon W2C Date 220914

Stage of Inspection Masked va(ve[ reg Blastingl Primer J Time 300PM

Procedure Ref PPSG-11ril DT 180914 Spec free of foreign particle

Item Description Masked valve [6cass6QO Gate-14G201033] after de~masking

Test Type Method I Acceptance middotmiddotmiddotmiddotmiddot1 Result I Remarks i ~~~~__~~ln~st~r~um~en~t~~~cn~middott~e~rt7middot~~~~~~~~__+70-===~~~__-------~IMasking Visual 1] No damage in masking tape 1Proper maskingmiddot Passed

effeciveness Inspection 2] Covered aU relevant areas I-wi~tgne=ss~ed~=-==-__-+-i inspection as per 3) No grit entry in to flow bore 2No damages -ensured Procedure 4J No metal damges on 3Masking practice comply

U Photographs serrationfr stem threads due to to the Procedure I a I blasting requirement i~checklist__-____________________--L

TESTED BY VERIFIED BY

A-~ tgto~ A VeWlIgiri QA PJayaramanl(Ji

Page 4 of 12

20 Background

3 valves of 2rdquo150 WCB Check valve amp 1 valve of 2rdquo300 WCB Gate supplied to Gasco - Habshan Direct

Depressurization on account of NAMA Mott was seat passing

Customer GASCO GASCO

Valve Type Check Gate

Valve size 2rdquo 2rdquo

Class 150 300

Material WCB LCB

Quantity 3 Nos

1 No

Main valve serial no 13902796 1390279713902798

13902240

Tag number VC-006 VG-003

Customer PO NMMP302901PO007 REV 2

NMMP302901PO007 REV 2

LampT Valves Sale Order Line item No

12000008120 800010410

30 Preliminary Analysis

Valve serial no 13902796 1390279713902798 13902240

Heat no 3H164 N3444

Foundry Auto Shell Cast Pvt Ltd Veeyes foundry

RT no LIR2602 LIR2603 LIR2601 VR1798

Test report verified verified

Page 5 of 12

We have verified the following the manufacturing documents

1) Test certificate verified

2) The above valves were tested internally by LampT Valves and offered to Third Party Inspection

agencies - RGopalasamy (NMM) amp KGopinath (Intertek) Valve test report verified and found

acceptable

3) All marking details were verified as per GADcustomer PO requirement

4) On completion of Pressure testing Valves were cleared and applied rust preventive and final

inspection done by QC and moved to grit blasting amp painting

5) Painting amp packing witnessed by approved TPI agency (inspected report enclosed)

6) Before dispatch (PDI) inspection carried out amp cleared Refer below photos

VTC - report

Page 6 of 12

40 Correction

It was reported that foreign particle may present inside the seat surfaces which leads to seat leakage in the valves

50 Root Cause Analysis

RCA - ROOT CAUSE ANALYSIS SHEET ndash GLAND LEAKAGE PROBLEM DESCRIPTION DESCRIPTION AREA DESCRIPTION DATA

WHAT

Seat leakage noticed Leakage was noticed during testing at site

WHERE Leak noticed in seat surfaces Leak noticed in disc amp seat ring seating surfaces

WHEN

pressure testing at site Leak noticed during pressure testing at required seat pressure

HOW BIG Visible leak found Leakage found in valve closed condition

Similar Parts Gate valve ndash 1 no Gate valve of 2rdquo300 class observed seat leak

Page 7 of 12

S No CAUSES SIGNIFICANT IN-

SIGNIFICANT

1 Improper masking with end cover while preparation of surfaces amp improper sealing of flow bores with end cover after completing of painting inspection

may cause foreign particle to enter

significant

2 Improper surface contact between the seat surfaces Insignificant

3 Rust preventive Gel brush contaminated by foreign particle Insignificant

4 In adequate surface finish between the seating surfaces Insignificant

5 Positioning amp locating the valve for surface preparation Insignificant

6 Improper cleaning at intrinsic areas Insignificant

7 Lack of awareness significant

8 Difference in hardness was not maintained Insignificant

CAUSE AND EFFECT DIAGRAM - DEFINE amp VERIFY ROOT CAUSE

MAN MATERIALS

METHODSPROCESSES MACHINE

PROBLEM

STATEMENT

Visible Seat

leakage at site

Improper masking improper sealing

with end cover

Improper cleaning at

intrinsic areas

Lack of Awareness amp

training

Difference in hardness was not

maintained

Improper surface contact

between the seat surfaces

In adequate surface finish between the

seating surfaces

Rust preventive gel brush

contaminated by foreign

particles

Positioning amp locating the valve for

surface preparation

Page 8 of 12

60 Verification

S No CAUSES Verification status

1 Improper masking

improper sealing

Valve to be properly masked during surface preparation amp to seal the ends

with end protector

2 Improper surface

contact

Contact surfaces were checked with blue matching were verified during

assembly stage

3 Contamination of RP Gel

brush

Clean amp dust free materials were used for applying the rust preventive

gels and follows the procedure

4 In adequate surface

finish

Surface finish was checked during assembly and follows as per procedure

5 Positioning amp locating Positioning amp locating the valves were checked and follows the procedure

for surface preparation

6 Improper cleaning at

intrinsic areas

Post cleaning was done after surface preparation and painting inspection

were carried out and found acceptable

7 Lack of awareness amp

training

Critical areas to check amp awareness on procedure to be followed before

packing the valves

8 Difference in hardness

was not maintained

Seating surface materials were found acceptable with required hardness

as per procedure

Page 9 of 12

70 Corrective action

Based on the above the following corrective actions are suggested

1 Additional care has been taken to avoid entering of foreign particles during grit blasting painting amp packing A separate SOP to be released on Grit blast masking

2 Photograph will be taken for each valve to ensure the cleanliness of internals after applying gel and same will be ensured during packing amp pre dispatch inspection

80 Action plan on Corrective Action 1 Significant cause for the complaint has been discussed with the Grit blasting and painting team

2 Training and awareness in standard operating procedure given for QC Grit blasting and painting

team

3 A separate SOP has been released on Grit blast masking (Refer attached)

Page 10 of 12

4 Training given on masking locations to the grit blasting team

5 Masking of body amp bonnet cover joints amp flow bore areas were done with readymade plaster masks Self-adhesive masking tapes for both raised face and Butt weld ends

6 Masking of stuffing box areas amp gear unit locations were done with good dense wax before preparing the surfaces through grit blasting

Page 11 of 12

7 Below images shows the rigidity of masking to restrict the entrance of foreign particles into the flow bore Masking done before blasting remains damage free even after completion of painting

8 End capprotector used after completion of painting application of rust preventive Gel and after QC inspection Same will be ensured during pre-Dispatch inspection

9 Training has been given to the concerns amp additional check has been made to ensure internals are free from foreign particles and recorded in a report(attached below)

Page 12 of 12

Enclosure

1) Test certificate

2) Valve test report

3) Painting inspection report

4) Packing inspection report

5) Training attendance sheet

6) Visual inspection report

Prepared by Approved by

KPradeep Raja C

Date 27102014

== End of report ==

LEtT VALVESLIMITED AUDIT CHECK INSPECTION REPORT REPORT ACO 1 0

Locatfon W2C Date 220914

Stage of Inspection Masked va(ve[ reg Blastingl Primer J Time 300PM

Procedure Ref PPSG-11ril DT 180914 Spec free of foreign particle

Item Description Masked valve [6cass6QO Gate-14G201033] after de~masking

Test Type Method I Acceptance middotmiddotmiddotmiddotmiddot1 Result I Remarks i ~~~~__~~ln~st~r~um~en~t~~~cn~middott~e~rt7middot~~~~~~~~__+70-===~~~__-------~IMasking Visual 1] No damage in masking tape 1Proper maskingmiddot Passed

effeciveness Inspection 2] Covered aU relevant areas I-wi~tgne=ss~ed~=-==-__-+-i inspection as per 3) No grit entry in to flow bore 2No damages -ensured Procedure 4J No metal damges on 3Masking practice comply

U Photographs serrationfr stem threads due to to the Procedure I a I blasting requirement i~checklist__-____________________--L

TESTED BY VERIFIED BY

A-~ tgto~ A VeWlIgiri QA PJayaramanl(Ji

Page 5 of 12

We have verified the following the manufacturing documents

1) Test certificate verified

2) The above valves were tested internally by LampT Valves and offered to Third Party Inspection

agencies - RGopalasamy (NMM) amp KGopinath (Intertek) Valve test report verified and found

acceptable

3) All marking details were verified as per GADcustomer PO requirement

4) On completion of Pressure testing Valves were cleared and applied rust preventive and final

inspection done by QC and moved to grit blasting amp painting

5) Painting amp packing witnessed by approved TPI agency (inspected report enclosed)

6) Before dispatch (PDI) inspection carried out amp cleared Refer below photos

VTC - report

Page 6 of 12

40 Correction

It was reported that foreign particle may present inside the seat surfaces which leads to seat leakage in the valves

50 Root Cause Analysis

RCA - ROOT CAUSE ANALYSIS SHEET ndash GLAND LEAKAGE PROBLEM DESCRIPTION DESCRIPTION AREA DESCRIPTION DATA

WHAT

Seat leakage noticed Leakage was noticed during testing at site

WHERE Leak noticed in seat surfaces Leak noticed in disc amp seat ring seating surfaces

WHEN

pressure testing at site Leak noticed during pressure testing at required seat pressure

HOW BIG Visible leak found Leakage found in valve closed condition

Similar Parts Gate valve ndash 1 no Gate valve of 2rdquo300 class observed seat leak

Page 7 of 12

S No CAUSES SIGNIFICANT IN-

SIGNIFICANT

1 Improper masking with end cover while preparation of surfaces amp improper sealing of flow bores with end cover after completing of painting inspection

may cause foreign particle to enter

significant

2 Improper surface contact between the seat surfaces Insignificant

3 Rust preventive Gel brush contaminated by foreign particle Insignificant

4 In adequate surface finish between the seating surfaces Insignificant

5 Positioning amp locating the valve for surface preparation Insignificant

6 Improper cleaning at intrinsic areas Insignificant

7 Lack of awareness significant

8 Difference in hardness was not maintained Insignificant

CAUSE AND EFFECT DIAGRAM - DEFINE amp VERIFY ROOT CAUSE

MAN MATERIALS

METHODSPROCESSES MACHINE

PROBLEM

STATEMENT

Visible Seat

leakage at site

Improper masking improper sealing

with end cover

Improper cleaning at

intrinsic areas

Lack of Awareness amp

training

Difference in hardness was not

maintained

Improper surface contact

between the seat surfaces

In adequate surface finish between the

seating surfaces

Rust preventive gel brush

contaminated by foreign

particles

Positioning amp locating the valve for

surface preparation

Page 8 of 12

60 Verification

S No CAUSES Verification status

1 Improper masking

improper sealing

Valve to be properly masked during surface preparation amp to seal the ends

with end protector

2 Improper surface

contact

Contact surfaces were checked with blue matching were verified during

assembly stage

3 Contamination of RP Gel

brush

Clean amp dust free materials were used for applying the rust preventive

gels and follows the procedure

4 In adequate surface

finish

Surface finish was checked during assembly and follows as per procedure

5 Positioning amp locating Positioning amp locating the valves were checked and follows the procedure

for surface preparation

6 Improper cleaning at

intrinsic areas

Post cleaning was done after surface preparation and painting inspection

were carried out and found acceptable

7 Lack of awareness amp

training

Critical areas to check amp awareness on procedure to be followed before

packing the valves

8 Difference in hardness

was not maintained

Seating surface materials were found acceptable with required hardness

as per procedure

Page 9 of 12

70 Corrective action

Based on the above the following corrective actions are suggested

1 Additional care has been taken to avoid entering of foreign particles during grit blasting painting amp packing A separate SOP to be released on Grit blast masking

2 Photograph will be taken for each valve to ensure the cleanliness of internals after applying gel and same will be ensured during packing amp pre dispatch inspection

80 Action plan on Corrective Action 1 Significant cause for the complaint has been discussed with the Grit blasting and painting team

2 Training and awareness in standard operating procedure given for QC Grit blasting and painting

team

3 A separate SOP has been released on Grit blast masking (Refer attached)

Page 10 of 12

4 Training given on masking locations to the grit blasting team

5 Masking of body amp bonnet cover joints amp flow bore areas were done with readymade plaster masks Self-adhesive masking tapes for both raised face and Butt weld ends

6 Masking of stuffing box areas amp gear unit locations were done with good dense wax before preparing the surfaces through grit blasting

Page 11 of 12

7 Below images shows the rigidity of masking to restrict the entrance of foreign particles into the flow bore Masking done before blasting remains damage free even after completion of painting

8 End capprotector used after completion of painting application of rust preventive Gel and after QC inspection Same will be ensured during pre-Dispatch inspection

9 Training has been given to the concerns amp additional check has been made to ensure internals are free from foreign particles and recorded in a report(attached below)

Page 12 of 12

Enclosure

1) Test certificate

2) Valve test report

3) Painting inspection report

4) Packing inspection report

5) Training attendance sheet

6) Visual inspection report

Prepared by Approved by

KPradeep Raja C

Date 27102014

== End of report ==

LEtT VALVESLIMITED AUDIT CHECK INSPECTION REPORT REPORT ACO 1 0

Locatfon W2C Date 220914

Stage of Inspection Masked va(ve[ reg Blastingl Primer J Time 300PM

Procedure Ref PPSG-11ril DT 180914 Spec free of foreign particle

Item Description Masked valve [6cass6QO Gate-14G201033] after de~masking

Test Type Method I Acceptance middotmiddotmiddotmiddotmiddot1 Result I Remarks i ~~~~__~~ln~st~r~um~en~t~~~cn~middott~e~rt7middot~~~~~~~~__+70-===~~~__-------~IMasking Visual 1] No damage in masking tape 1Proper maskingmiddot Passed

effeciveness Inspection 2] Covered aU relevant areas I-wi~tgne=ss~ed~=-==-__-+-i inspection as per 3) No grit entry in to flow bore 2No damages -ensured Procedure 4J No metal damges on 3Masking practice comply

U Photographs serrationfr stem threads due to to the Procedure I a I blasting requirement i~checklist__-____________________--L

TESTED BY VERIFIED BY

A-~ tgto~ A VeWlIgiri QA PJayaramanl(Ji

Page 6 of 12

40 Correction

It was reported that foreign particle may present inside the seat surfaces which leads to seat leakage in the valves

50 Root Cause Analysis

RCA - ROOT CAUSE ANALYSIS SHEET ndash GLAND LEAKAGE PROBLEM DESCRIPTION DESCRIPTION AREA DESCRIPTION DATA

WHAT

Seat leakage noticed Leakage was noticed during testing at site

WHERE Leak noticed in seat surfaces Leak noticed in disc amp seat ring seating surfaces

WHEN

pressure testing at site Leak noticed during pressure testing at required seat pressure

HOW BIG Visible leak found Leakage found in valve closed condition

Similar Parts Gate valve ndash 1 no Gate valve of 2rdquo300 class observed seat leak

Page 7 of 12

S No CAUSES SIGNIFICANT IN-

SIGNIFICANT

1 Improper masking with end cover while preparation of surfaces amp improper sealing of flow bores with end cover after completing of painting inspection

may cause foreign particle to enter

significant

2 Improper surface contact between the seat surfaces Insignificant

3 Rust preventive Gel brush contaminated by foreign particle Insignificant

4 In adequate surface finish between the seating surfaces Insignificant

5 Positioning amp locating the valve for surface preparation Insignificant

6 Improper cleaning at intrinsic areas Insignificant

7 Lack of awareness significant

8 Difference in hardness was not maintained Insignificant

CAUSE AND EFFECT DIAGRAM - DEFINE amp VERIFY ROOT CAUSE

MAN MATERIALS

METHODSPROCESSES MACHINE

PROBLEM

STATEMENT

Visible Seat

leakage at site

Improper masking improper sealing

with end cover

Improper cleaning at

intrinsic areas

Lack of Awareness amp

training

Difference in hardness was not

maintained

Improper surface contact

between the seat surfaces

In adequate surface finish between the

seating surfaces

Rust preventive gel brush

contaminated by foreign

particles

Positioning amp locating the valve for

surface preparation

Page 8 of 12

60 Verification

S No CAUSES Verification status

1 Improper masking

improper sealing

Valve to be properly masked during surface preparation amp to seal the ends

with end protector

2 Improper surface

contact

Contact surfaces were checked with blue matching were verified during

assembly stage

3 Contamination of RP Gel

brush

Clean amp dust free materials were used for applying the rust preventive

gels and follows the procedure

4 In adequate surface

finish

Surface finish was checked during assembly and follows as per procedure

5 Positioning amp locating Positioning amp locating the valves were checked and follows the procedure

for surface preparation

6 Improper cleaning at

intrinsic areas

Post cleaning was done after surface preparation and painting inspection

were carried out and found acceptable

7 Lack of awareness amp

training

Critical areas to check amp awareness on procedure to be followed before

packing the valves

8 Difference in hardness

was not maintained

Seating surface materials were found acceptable with required hardness

as per procedure

Page 9 of 12

70 Corrective action

Based on the above the following corrective actions are suggested

1 Additional care has been taken to avoid entering of foreign particles during grit blasting painting amp packing A separate SOP to be released on Grit blast masking

2 Photograph will be taken for each valve to ensure the cleanliness of internals after applying gel and same will be ensured during packing amp pre dispatch inspection

80 Action plan on Corrective Action 1 Significant cause for the complaint has been discussed with the Grit blasting and painting team

2 Training and awareness in standard operating procedure given for QC Grit blasting and painting

team

3 A separate SOP has been released on Grit blast masking (Refer attached)

Page 10 of 12

4 Training given on masking locations to the grit blasting team

5 Masking of body amp bonnet cover joints amp flow bore areas were done with readymade plaster masks Self-adhesive masking tapes for both raised face and Butt weld ends

6 Masking of stuffing box areas amp gear unit locations were done with good dense wax before preparing the surfaces through grit blasting

Page 11 of 12

7 Below images shows the rigidity of masking to restrict the entrance of foreign particles into the flow bore Masking done before blasting remains damage free even after completion of painting

8 End capprotector used after completion of painting application of rust preventive Gel and after QC inspection Same will be ensured during pre-Dispatch inspection

9 Training has been given to the concerns amp additional check has been made to ensure internals are free from foreign particles and recorded in a report(attached below)

Page 12 of 12

Enclosure

1) Test certificate

2) Valve test report

3) Painting inspection report

4) Packing inspection report

5) Training attendance sheet

6) Visual inspection report

Prepared by Approved by

KPradeep Raja C

Date 27102014

== End of report ==

LEtT VALVESLIMITED AUDIT CHECK INSPECTION REPORT REPORT ACO 1 0

Locatfon W2C Date 220914

Stage of Inspection Masked va(ve[ reg Blastingl Primer J Time 300PM

Procedure Ref PPSG-11ril DT 180914 Spec free of foreign particle

Item Description Masked valve [6cass6QO Gate-14G201033] after de~masking

Test Type Method I Acceptance middotmiddotmiddotmiddotmiddot1 Result I Remarks i ~~~~__~~ln~st~r~um~en~t~~~cn~middott~e~rt7middot~~~~~~~~__+70-===~~~__-------~IMasking Visual 1] No damage in masking tape 1Proper maskingmiddot Passed

effeciveness Inspection 2] Covered aU relevant areas I-wi~tgne=ss~ed~=-==-__-+-i inspection as per 3) No grit entry in to flow bore 2No damages -ensured Procedure 4J No metal damges on 3Masking practice comply

U Photographs serrationfr stem threads due to to the Procedure I a I blasting requirement i~checklist__-____________________--L

TESTED BY VERIFIED BY

A-~ tgto~ A VeWlIgiri QA PJayaramanl(Ji

Page 7 of 12

S No CAUSES SIGNIFICANT IN-

SIGNIFICANT

1 Improper masking with end cover while preparation of surfaces amp improper sealing of flow bores with end cover after completing of painting inspection

may cause foreign particle to enter

significant

2 Improper surface contact between the seat surfaces Insignificant

3 Rust preventive Gel brush contaminated by foreign particle Insignificant

4 In adequate surface finish between the seating surfaces Insignificant

5 Positioning amp locating the valve for surface preparation Insignificant

6 Improper cleaning at intrinsic areas Insignificant

7 Lack of awareness significant

8 Difference in hardness was not maintained Insignificant

CAUSE AND EFFECT DIAGRAM - DEFINE amp VERIFY ROOT CAUSE

MAN MATERIALS

METHODSPROCESSES MACHINE

PROBLEM

STATEMENT

Visible Seat

leakage at site

Improper masking improper sealing

with end cover

Improper cleaning at

intrinsic areas

Lack of Awareness amp

training

Difference in hardness was not

maintained

Improper surface contact

between the seat surfaces

In adequate surface finish between the

seating surfaces

Rust preventive gel brush

contaminated by foreign

particles

Positioning amp locating the valve for

surface preparation

Page 8 of 12

60 Verification

S No CAUSES Verification status

1 Improper masking

improper sealing

Valve to be properly masked during surface preparation amp to seal the ends

with end protector

2 Improper surface

contact

Contact surfaces were checked with blue matching were verified during

assembly stage

3 Contamination of RP Gel

brush

Clean amp dust free materials were used for applying the rust preventive

gels and follows the procedure

4 In adequate surface

finish

Surface finish was checked during assembly and follows as per procedure

5 Positioning amp locating Positioning amp locating the valves were checked and follows the procedure

for surface preparation

6 Improper cleaning at

intrinsic areas

Post cleaning was done after surface preparation and painting inspection

were carried out and found acceptable

7 Lack of awareness amp

training

Critical areas to check amp awareness on procedure to be followed before

packing the valves

8 Difference in hardness

was not maintained

Seating surface materials were found acceptable with required hardness

as per procedure

Page 9 of 12

70 Corrective action

Based on the above the following corrective actions are suggested

1 Additional care has been taken to avoid entering of foreign particles during grit blasting painting amp packing A separate SOP to be released on Grit blast masking

2 Photograph will be taken for each valve to ensure the cleanliness of internals after applying gel and same will be ensured during packing amp pre dispatch inspection

80 Action plan on Corrective Action 1 Significant cause for the complaint has been discussed with the Grit blasting and painting team

2 Training and awareness in standard operating procedure given for QC Grit blasting and painting

team

3 A separate SOP has been released on Grit blast masking (Refer attached)

Page 10 of 12

4 Training given on masking locations to the grit blasting team

5 Masking of body amp bonnet cover joints amp flow bore areas were done with readymade plaster masks Self-adhesive masking tapes for both raised face and Butt weld ends

6 Masking of stuffing box areas amp gear unit locations were done with good dense wax before preparing the surfaces through grit blasting

Page 11 of 12

7 Below images shows the rigidity of masking to restrict the entrance of foreign particles into the flow bore Masking done before blasting remains damage free even after completion of painting

8 End capprotector used after completion of painting application of rust preventive Gel and after QC inspection Same will be ensured during pre-Dispatch inspection

9 Training has been given to the concerns amp additional check has been made to ensure internals are free from foreign particles and recorded in a report(attached below)

Page 12 of 12

Enclosure

1) Test certificate

2) Valve test report

3) Painting inspection report

4) Packing inspection report

5) Training attendance sheet

6) Visual inspection report

Prepared by Approved by

KPradeep Raja C

Date 27102014

== End of report ==

LEtT VALVESLIMITED AUDIT CHECK INSPECTION REPORT REPORT ACO 1 0

Locatfon W2C Date 220914

Stage of Inspection Masked va(ve[ reg Blastingl Primer J Time 300PM

Procedure Ref PPSG-11ril DT 180914 Spec free of foreign particle

Item Description Masked valve [6cass6QO Gate-14G201033] after de~masking

Test Type Method I Acceptance middotmiddotmiddotmiddotmiddot1 Result I Remarks i ~~~~__~~ln~st~r~um~en~t~~~cn~middott~e~rt7middot~~~~~~~~__+70-===~~~__-------~IMasking Visual 1] No damage in masking tape 1Proper maskingmiddot Passed

effeciveness Inspection 2] Covered aU relevant areas I-wi~tgne=ss~ed~=-==-__-+-i inspection as per 3) No grit entry in to flow bore 2No damages -ensured Procedure 4J No metal damges on 3Masking practice comply

U Photographs serrationfr stem threads due to to the Procedure I a I blasting requirement i~checklist__-____________________--L

TESTED BY VERIFIED BY

A-~ tgto~ A VeWlIgiri QA PJayaramanl(Ji

Page 8 of 12

60 Verification

S No CAUSES Verification status

1 Improper masking

improper sealing

Valve to be properly masked during surface preparation amp to seal the ends

with end protector

2 Improper surface

contact

Contact surfaces were checked with blue matching were verified during

assembly stage

3 Contamination of RP Gel

brush

Clean amp dust free materials were used for applying the rust preventive

gels and follows the procedure

4 In adequate surface

finish

Surface finish was checked during assembly and follows as per procedure

5 Positioning amp locating Positioning amp locating the valves were checked and follows the procedure

for surface preparation

6 Improper cleaning at

intrinsic areas

Post cleaning was done after surface preparation and painting inspection

were carried out and found acceptable

7 Lack of awareness amp

training

Critical areas to check amp awareness on procedure to be followed before

packing the valves

8 Difference in hardness

was not maintained

Seating surface materials were found acceptable with required hardness

as per procedure

Page 9 of 12

70 Corrective action

Based on the above the following corrective actions are suggested

1 Additional care has been taken to avoid entering of foreign particles during grit blasting painting amp packing A separate SOP to be released on Grit blast masking

2 Photograph will be taken for each valve to ensure the cleanliness of internals after applying gel and same will be ensured during packing amp pre dispatch inspection

80 Action plan on Corrective Action 1 Significant cause for the complaint has been discussed with the Grit blasting and painting team

2 Training and awareness in standard operating procedure given for QC Grit blasting and painting

team

3 A separate SOP has been released on Grit blast masking (Refer attached)

Page 10 of 12

4 Training given on masking locations to the grit blasting team

5 Masking of body amp bonnet cover joints amp flow bore areas were done with readymade plaster masks Self-adhesive masking tapes for both raised face and Butt weld ends

6 Masking of stuffing box areas amp gear unit locations were done with good dense wax before preparing the surfaces through grit blasting

Page 11 of 12

7 Below images shows the rigidity of masking to restrict the entrance of foreign particles into the flow bore Masking done before blasting remains damage free even after completion of painting

8 End capprotector used after completion of painting application of rust preventive Gel and after QC inspection Same will be ensured during pre-Dispatch inspection

9 Training has been given to the concerns amp additional check has been made to ensure internals are free from foreign particles and recorded in a report(attached below)

Page 12 of 12

Enclosure

1) Test certificate

2) Valve test report

3) Painting inspection report

4) Packing inspection report

5) Training attendance sheet

6) Visual inspection report

Prepared by Approved by

KPradeep Raja C

Date 27102014

== End of report ==

LEtT VALVESLIMITED AUDIT CHECK INSPECTION REPORT REPORT ACO 1 0

Locatfon W2C Date 220914

Stage of Inspection Masked va(ve[ reg Blastingl Primer J Time 300PM

Procedure Ref PPSG-11ril DT 180914 Spec free of foreign particle

Item Description Masked valve [6cass6QO Gate-14G201033] after de~masking

Test Type Method I Acceptance middotmiddotmiddotmiddotmiddot1 Result I Remarks i ~~~~__~~ln~st~r~um~en~t~~~cn~middott~e~rt7middot~~~~~~~~__+70-===~~~__-------~IMasking Visual 1] No damage in masking tape 1Proper maskingmiddot Passed

effeciveness Inspection 2] Covered aU relevant areas I-wi~tgne=ss~ed~=-==-__-+-i inspection as per 3) No grit entry in to flow bore 2No damages -ensured Procedure 4J No metal damges on 3Masking practice comply

U Photographs serrationfr stem threads due to to the Procedure I a I blasting requirement i~checklist__-____________________--L

TESTED BY VERIFIED BY

A-~ tgto~ A VeWlIgiri QA PJayaramanl(Ji

Page 9 of 12

70 Corrective action

Based on the above the following corrective actions are suggested

1 Additional care has been taken to avoid entering of foreign particles during grit blasting painting amp packing A separate SOP to be released on Grit blast masking

2 Photograph will be taken for each valve to ensure the cleanliness of internals after applying gel and same will be ensured during packing amp pre dispatch inspection

80 Action plan on Corrective Action 1 Significant cause for the complaint has been discussed with the Grit blasting and painting team

2 Training and awareness in standard operating procedure given for QC Grit blasting and painting

team

3 A separate SOP has been released on Grit blast masking (Refer attached)

Page 10 of 12

4 Training given on masking locations to the grit blasting team

5 Masking of body amp bonnet cover joints amp flow bore areas were done with readymade plaster masks Self-adhesive masking tapes for both raised face and Butt weld ends

6 Masking of stuffing box areas amp gear unit locations were done with good dense wax before preparing the surfaces through grit blasting

Page 11 of 12

7 Below images shows the rigidity of masking to restrict the entrance of foreign particles into the flow bore Masking done before blasting remains damage free even after completion of painting

8 End capprotector used after completion of painting application of rust preventive Gel and after QC inspection Same will be ensured during pre-Dispatch inspection

9 Training has been given to the concerns amp additional check has been made to ensure internals are free from foreign particles and recorded in a report(attached below)

Page 12 of 12

Enclosure

1) Test certificate

2) Valve test report

3) Painting inspection report

4) Packing inspection report

5) Training attendance sheet

6) Visual inspection report

Prepared by Approved by

KPradeep Raja C

Date 27102014

== End of report ==

LEtT VALVESLIMITED AUDIT CHECK INSPECTION REPORT REPORT ACO 1 0

Locatfon W2C Date 220914

Stage of Inspection Masked va(ve[ reg Blastingl Primer J Time 300PM

Procedure Ref PPSG-11ril DT 180914 Spec free of foreign particle

Item Description Masked valve [6cass6QO Gate-14G201033] after de~masking

Test Type Method I Acceptance middotmiddotmiddotmiddotmiddot1 Result I Remarks i ~~~~__~~ln~st~r~um~en~t~~~cn~middott~e~rt7middot~~~~~~~~__+70-===~~~__-------~IMasking Visual 1] No damage in masking tape 1Proper maskingmiddot Passed

effeciveness Inspection 2] Covered aU relevant areas I-wi~tgne=ss~ed~=-==-__-+-i inspection as per 3) No grit entry in to flow bore 2No damages -ensured Procedure 4J No metal damges on 3Masking practice comply

U Photographs serrationfr stem threads due to to the Procedure I a I blasting requirement i~checklist__-____________________--L

TESTED BY VERIFIED BY

A-~ tgto~ A VeWlIgiri QA PJayaramanl(Ji

Page 10 of 12

4 Training given on masking locations to the grit blasting team

5 Masking of body amp bonnet cover joints amp flow bore areas were done with readymade plaster masks Self-adhesive masking tapes for both raised face and Butt weld ends

6 Masking of stuffing box areas amp gear unit locations were done with good dense wax before preparing the surfaces through grit blasting

Page 11 of 12

7 Below images shows the rigidity of masking to restrict the entrance of foreign particles into the flow bore Masking done before blasting remains damage free even after completion of painting

8 End capprotector used after completion of painting application of rust preventive Gel and after QC inspection Same will be ensured during pre-Dispatch inspection

9 Training has been given to the concerns amp additional check has been made to ensure internals are free from foreign particles and recorded in a report(attached below)

Page 12 of 12

Enclosure

1) Test certificate

2) Valve test report

3) Painting inspection report

4) Packing inspection report

5) Training attendance sheet

6) Visual inspection report

Prepared by Approved by

KPradeep Raja C

Date 27102014

== End of report ==

LEtT VALVESLIMITED AUDIT CHECK INSPECTION REPORT REPORT ACO 1 0

Locatfon W2C Date 220914

Stage of Inspection Masked va(ve[ reg Blastingl Primer J Time 300PM

Procedure Ref PPSG-11ril DT 180914 Spec free of foreign particle

Item Description Masked valve [6cass6QO Gate-14G201033] after de~masking

Test Type Method I Acceptance middotmiddotmiddotmiddotmiddot1 Result I Remarks i ~~~~__~~ln~st~r~um~en~t~~~cn~middott~e~rt7middot~~~~~~~~__+70-===~~~__-------~IMasking Visual 1] No damage in masking tape 1Proper maskingmiddot Passed

effeciveness Inspection 2] Covered aU relevant areas I-wi~tgne=ss~ed~=-==-__-+-i inspection as per 3) No grit entry in to flow bore 2No damages -ensured Procedure 4J No metal damges on 3Masking practice comply

U Photographs serrationfr stem threads due to to the Procedure I a I blasting requirement i~checklist__-____________________--L

TESTED BY VERIFIED BY

A-~ tgto~ A VeWlIgiri QA PJayaramanl(Ji

Page 11 of 12

7 Below images shows the rigidity of masking to restrict the entrance of foreign particles into the flow bore Masking done before blasting remains damage free even after completion of painting

8 End capprotector used after completion of painting application of rust preventive Gel and after QC inspection Same will be ensured during pre-Dispatch inspection

9 Training has been given to the concerns amp additional check has been made to ensure internals are free from foreign particles and recorded in a report(attached below)

Page 12 of 12

Enclosure

1) Test certificate

2) Valve test report

3) Painting inspection report

4) Packing inspection report

5) Training attendance sheet

6) Visual inspection report

Prepared by Approved by

KPradeep Raja C

Date 27102014

== End of report ==

LEtT VALVESLIMITED AUDIT CHECK INSPECTION REPORT REPORT ACO 1 0

Locatfon W2C Date 220914

Stage of Inspection Masked va(ve[ reg Blastingl Primer J Time 300PM

Procedure Ref PPSG-11ril DT 180914 Spec free of foreign particle

Item Description Masked valve [6cass6QO Gate-14G201033] after de~masking

Test Type Method I Acceptance middotmiddotmiddotmiddotmiddot1 Result I Remarks i ~~~~__~~ln~st~r~um~en~t~~~cn~middott~e~rt7middot~~~~~~~~__+70-===~~~__-------~IMasking Visual 1] No damage in masking tape 1Proper maskingmiddot Passed

effeciveness Inspection 2] Covered aU relevant areas I-wi~tgne=ss~ed~=-==-__-+-i inspection as per 3) No grit entry in to flow bore 2No damages -ensured Procedure 4J No metal damges on 3Masking practice comply

U Photographs serrationfr stem threads due to to the Procedure I a I blasting requirement i~checklist__-____________________--L

TESTED BY VERIFIED BY

A-~ tgto~ A VeWlIgiri QA PJayaramanl(Ji

Page 12 of 12

Enclosure

1) Test certificate

2) Valve test report

3) Painting inspection report

4) Packing inspection report

5) Training attendance sheet

6) Visual inspection report

Prepared by Approved by

KPradeep Raja C

Date 27102014

== End of report ==

LEtT VALVESLIMITED AUDIT CHECK INSPECTION REPORT REPORT ACO 1 0

Locatfon W2C Date 220914

Stage of Inspection Masked va(ve[ reg Blastingl Primer J Time 300PM

Procedure Ref PPSG-11ril DT 180914 Spec free of foreign particle

Item Description Masked valve [6cass6QO Gate-14G201033] after de~masking

Test Type Method I Acceptance middotmiddotmiddotmiddotmiddot1 Result I Remarks i ~~~~__~~ln~st~r~um~en~t~~~cn~middott~e~rt7middot~~~~~~~~__+70-===~~~__-------~IMasking Visual 1] No damage in masking tape 1Proper maskingmiddot Passed

effeciveness Inspection 2] Covered aU relevant areas I-wi~tgne=ss~ed~=-==-__-+-i inspection as per 3) No grit entry in to flow bore 2No damages -ensured Procedure 4J No metal damges on 3Masking practice comply

U Photographs serrationfr stem threads due to to the Procedure I a I blasting requirement i~checklist__-____________________--L

TESTED BY VERIFIED BY

A-~ tgto~ A VeWlIgiri QA PJayaramanl(Ji

LEtT VALVESLIMITED AUDIT CHECK INSPECTION REPORT REPORT ACO 1 0

Locatfon W2C Date 220914

Stage of Inspection Masked va(ve[ reg Blastingl Primer J Time 300PM

Procedure Ref PPSG-11ril DT 180914 Spec free of foreign particle

Item Description Masked valve [6cass6QO Gate-14G201033] after de~masking

Test Type Method I Acceptance middotmiddotmiddotmiddotmiddot1 Result I Remarks i ~~~~__~~ln~st~r~um~en~t~~~cn~middott~e~rt7middot~~~~~~~~__+70-===~~~__-------~IMasking Visual 1] No damage in masking tape 1Proper maskingmiddot Passed

effeciveness Inspection 2] Covered aU relevant areas I-wi~tgne=ss~ed~=-==-__-+-i inspection as per 3) No grit entry in to flow bore 2No damages -ensured Procedure 4J No metal damges on 3Masking practice comply

U Photographs serrationfr stem threads due to to the Procedure I a I blasting requirement i~checklist__-____________________--L

TESTED BY VERIFIED BY

A-~ tgto~ A VeWlIgiri QA PJayaramanl(Ji