REPORT ON ROOT CAUSE ANALYSIS ON VALVE SEAT LEAK OBSERVED AT SAUDI ARAMCO REROUTE PIPELINE IN RASTANURA AREA PROJECT

Size: px

Start display at page:

Download "REPORT ON ROOT CAUSE ANALYSIS ON VALVE SEAT LEAK OBSERVED AT SAUDI ARAMCO REROUTE PIPELINE IN RASTANURA AREA PROJECT"

Warren Garrett
5 years ago
Views:

1 REPORT ON ROOT CAUSE ANALYSIS ON VALVE SEAT LEAK OBSERVED AT SAUDI ARAMCO REROUTE PIPELINE IN RASTANURA AREA PROJECT Team Members: Hari K S - Sr. DGM - Quality Control Sankar P Sr. DGM- Production Kandasaami CMS - DGM- Production Vijayarangan M Manager- Quality Control Murugavel N Assistant Manager- Production Bharath Kumar Badari Senior Engineer-Quality Control RCA REF: SC/CPP/REV.00 DT

2 CONTENTS 1.0 Background 2.0 Preliminary Analysis & Interim Containment Action 2.1 Verifications at L&T Valves Factory 2.2 Correction 3.0 Root Cause Analysis for Seat Leak 3.1 Problem Description Seat Leak 3.2 Cause and Effect Diagram Seat Leak 3.3 Significant Causes Seat Leak 3.4 Why Why analysis for Seat Leak 4.0 Corrective action at LTVL 5.0 corrective action at Site 2

3 1.0 Background: M/s China Petroleum Pipeline Engineering Co. LTD reported seat leakage during field hydro testing on TMBV Valves supplied by L&T Valves Ltd for Saudi Aramco Reroute Pipeline in RasTanura Area Project. Complaint References: Valve Test Report from Site Certificate No: /21 Date 4 July /18 Date 4 July /17 Date 4 July 2018 Mail Reference from Mr. Tony Wang, Procurement, CPP Dated 7th July NCR No. CPP-Mech-021 Dt Valve Details: Valve Description TMBVSS-2"600-2PFB-RF-WCB-F6A-WR Material Construction ASTM A216 Gr. WCB Valve Type Trunnion Mounted Ball Valve Sale Order/ Line Item /21 CPP Item No 1.02 Alruquee Item No 1.02 Valve Serial No 18C & 18C Valve QTY 2 No s Leakage Details Valve Found Leakage in Upstream & Down Stream Seat area. Valve Description TMBVSS-2"600-2PFB-RF-WCB-F6A-WR Material Construction ASTM A216 Gr. WCB Valve Type Trunnion Mounted Ball Valve Sale Order/ Line Item /51 CPP Item No 1.11 Alruquee Item No 1.05 Valve Serial No 18C Valve QTY 1 No Leakage Details Valve Found Leakage in Upstream & Down Stream Seat area. 3

4 2.0 Preliminary Analysis & Interim Containment Action: 2.1 Verifications at L&T Valves Factory: The following documents were verified and found in order: Inspection Test Plan (Annexure-1) General Assembly Drawing (Annexure-2) Internal Valve Test Reports (Annexure 3) SCN report (Annexure 4) Valve Hydro offer list duly signed by Aramco Overseas Company Inspector (Annexure 5) Pre Dispatch Inspection Report (Annexure 6) Pre Dispatch Inspection Photos (Annexure 7) In addition to the above we have verified all other relevant internal quality documents from receipt to final related to these valves and found meeting specifications and Approved Inspection Test Plan requirements The above valves were internally tested at L&T Valves as per approved ITP and Aramco Specification 04-SAMSS-048 and found accepted. Valves are pressure tested as per the sequence mentioned in the 04-SAMSS-048. TMBVSS-2"600-2PFB-RF-WCB-F6A-WR: Shell test 2225 Psig for 2 Minutes Double Block and Bleed test 1630 Psig for 2 Minutes Seat test Hydro 1630 psig for 2 Minutes Seat Test- Pneumatic- 80 Psig for 2 Minutes No leakage was reported in any of these tests at LTVL shop. 4

5 2.1.3 Out of 3 leaked valves, 1 Valve was hydro offered & witnessed by LSTK/AAI inspector at L&T shop before dispatch. Refer Annexure 5 for the complete offer list duly signed by TPI. Product Description TMBVSS- 2"600-2PFB- RF-WCB- F6A-WR Leaked Valve SL No PO Item No 18C C Offered LOT Qty. CPP TPI Witness ARAMCO TPI WITNESS C Remarks Witnessed By TPI as Sample Not Witness- Covered Under the Sample Not Witness- Covered Under the Sample 2.2 Correction: LTVL has already moved the leaked valves to Mod shop for repair and testing. LTVL QC engineer visited to M/s. AVMCO Service shop on 24 th July 2018 and observed minor scratches on the ball and seat. Recommended to do minor lapping, cleaning and retesting to ensure the seat leak. 5

6 3.0 Root Cause Analysis for Seat Leak: 3.1 Problem description for Seat Leak: RCA - ROOT CAUSE ANALYSIS SHEET WHAT DESCRIPTION OF THE PROBLEM What is the Discrepancy? Seat Leak. DESCRIPTION DATA Where specifically on the Discrepancy? Valve seat area WHERE Where geographically is the Discrepancy observed? At Customer site (for Saudi Aramco Reroute Pipeline in RasTanura Area Project) First seen - By the customer? Yes WHEN When seen since? July 2018 When is the Discrepancy seen? Seat leakage during field hydrostatic testing of valves at Customer test shop. HOW BIG How many Valves have the Discrepancy? 3 Nos. 6

7 3.2 Cause and Effect Diagram Seat Leak CAUSE AND EFFECT DIAGRAM CAUSE AND EFFECT DIAGRAM - DEFINE & VERIFY ROOT CAUSE MAN MACHINE Wrong test arrangement Not suitable for testing Inadequate Knowledge of Tester & Assembler Excess clamping pressure Improper Handling at site Lack of contact on seating surface (Blue match) Pressure pump with no control mechanism In correct disc machining & machine accuracy. Damage on the ball seat surface. PROBLEM STATEMENT Seat leakage observed during Site Testing in TMBV Scoring Mark on seat surfaces Internal rusting Body /disc - Poor Machining & lapping Contamination in DM Water METHODS MATERIALS 7

8 3.3 Significant Causes Seat Leak S No CAUSES SIGNIFICANT / IN- SIGNIFICANT 1 Inadequate Knowledge of Tester & Assembler INSIGNIFICANT 2 Improper Handling at site INSIGNIFICANT 3 Wrong test arrangement Not suitable for testing INSIGNIFICANT 4 Excess clamping pressure INSIGNIFICANT 5 Pressure pump with no control mechanism INSIGNIFICANT 6 In correct disc machining & machine accuracy INSIGNIFICANT 7 Lack of contact on seating surface (Blue match) INSIGNIFICANT 8 Internal rusting INSIGNIFICANT 9 Body /Disc - Poor Machining & lapping INSIGNIFICANT 10 Scoring Marks on the seat surface INSIGNIFICANT 11 Damage on the ball seat surface SIGNIFICANT 12 Contamination in DM water INSIGNIFICANT 8

0 Corrective actions at LTVL Based on earlier learnings & feedback from site, we have taken many improvement initiatives in the area of storage, preservations, phosphating etc In addition to the

9 3.4 Why-Why Analysis Significant Cause (Seat Leak) Damage on the ball seat surface Why? Scoring Marks on the seat surfaces Why? Foreign particles present on the seat Sealing Surface causing scratch during testing. Why? Valves are not stored & preserved properly. Root Cause: Damage on the ball seat surface. 4.0 Corrective actions at LTVL Based on earlier learnings & feedback from site, we have taken many improvement initiatives in the area of storage, preservations, phosphating etc In addition to the above, following further corrective actions are underway. Protection of set surfaces of TMBV valves by using tapes after internal testing till final inspection. The tape will be removed prior to dispatch. Implemented from 10 th May TMBV Masking Tape at Seat Sealing Location 5.0 Corrective actions at site LTVL Quality engineer is visiting all the major sites for training and handholding the site testing team and for proper preservation on a regular basis. = = End of Report = = 9

REPORT ON ROOT CAUSE ANALYSIS OF VALVES SEAT LEAK WHILE SITE TESTING.

REPORT ON ROOT CAUSE ANALYSIS OF VALVES SEAT LEAK WHILE SITE TESTING. REF EDRs: 02250-SITE-NCR-056-VENDOR L&T & 02250-SITE-NCR-061-VENDOR L&T Team Members: Hari K S Sr. DGM Head Quality Control. Suresh