INTERIM REPORT ON ROOT CAUSE ANALYSIS ON VALVE STRUCK DURING OPERATION OBSERVED AT ARKAD

ENGINEERING & CONSTRUCTION COMPANY, FADHILI DOWNSTREAM PIPELINES PROJECT

Team Members:

Hari K S - Sr. DGM - Quality Control

Suresh J - Sr. DGM- Production

Gopalakrishnan S – DGM - Quality Control

Ganesh kumar – AGM, Manufacturing

Ramajeyam K – Manager- Quality Control

Sivasankaran C – Manager – FG Stores

RCA REF: 120002563 REV.0 (DT. 27TH NOV 2018)

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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 Valve Struck

3.1 Problem Description –Valve struck

3.2 Cause and Effect Diagram Valve struck

3.3 Significant Causes Valve struck

3.4 Why Why analysis for Valve struck

4.0 Product & process verification at LTVL

5.0 Further Investigation

6.0 Conclusion

7.0 corrective action at Site

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1.0 Background:

M/s Arkad Engineering & construction company reported that valve is damaged during operating by operational people inside WGP & valve is no more functional on L&T Valves supplied Globe valve for Fadhili downstream Pipelines project. Mail References: E- MAIL from M/s Arkad Engineering and construction company IMRAN HAQ

Dated: 7th Oct 2018.

Valve Details:

2.0 Preliminary Analysis & Interim Containment Action:

2.1 Verifications at L&T Valves Factory:

2.1.1 The following documents were verified and found in order:

Inspection Test Plan

General Assembly Drawing

Internal Valve Test Report

Internal coating inspection report – Witness by Aramco Inspector

SCN – Final inspection report

Valve Hydro offer list duly signed by Aramco Inspector

Painting & Packing Report

Pre Dispatch Inspection Report

Pre Dispatch Inspection Photographs

Valve Description GLOBE-6"-CL300-FF-WCB-254SMO+HS-GU

Material Construction ASTM A216 Gr. WCB with internal Belzona

Valve Type Globe valve

Valve Serial No 18C200168

Order Qty. 36 Nos.

Delivered Qty. 36 Nos.

NCR Qty. 01 No.

Leakage Details Valve not functional

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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.

2.1.2 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.

Shell test – 1125 Psig for 5 Minutes & 15 Minutes

Seat test –Hydro – 815 psig for 1 Minutes

No leakage was reported in any of these tests at LTVL shop.

Observation on the valve :-

LTVL Service Engineer requested Arkad Engineering to move the valves to

AVIMCO Mod shop and he visited on 29th Oct 2018 and he done a detailed

study along with Avimco personnel and sent initial inspection report with

observation on 29th oct 2018.

Leaked valves moved to AVIMCO service shop & observed as below.

The following are the observations while dismantling at Mod shop under the

supervision of L&T valves service engineer on 29th Oct 2018.

a. Guide rib which was Ni coated was found to be cut either using

cutter or gouged.

b. We are able to see Ni coating above the cut lengthy and below cut

smaller.

c. Heavy burr observed on the cut portion

d. These are 100% witnessed by TPIs at various stages starting from

RMO, FBE witness , hydro till packing. (LSTK – Techmas & Aramco – Intertek)

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2.2 Correction:

Considering the damaged condition of the valve, it is recommended to replace

with the fresh valve.

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3.0 Root Cause Analysis for Valve Struck during operation:

3.1 Problem description for Valve Struck during operation:

RCA - ROOT CAUSE ANALYSIS SHEET

DESCRIPTION OF THE PROBLEM DESCRIPTION DATA

WHAT What is the Discrepancy? Valve got struck during operation.

WHERE

Where specifically on the

Discrepancy?

Where geographically is the

Discrepancy observed?

Valve operation(Open/Close)

At Customer site (for Fadhili downstream Pipelines

project site)

WHEN

First seen - By the customer? Yes

When seen since? Oct 2018

When is the Discrepancy seen? Valve struck and not operational

HOW

BIG

How many Valves have the

Discrepancy? 01 No.

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3.2 Cause and Effect Diagram –Valve struck during operation.

3.2.2 CAUSE AND EFFECT DIAGRAM

METHODS MATERIALS

MAN MACHINE

PROBLEM

STATEMENT

CAUSE AND EFFECT DIAGRAM - DEFINE & VERIFY ROOT CAUSE

Valve

struck and

not

operational

during

open/Close

Inadequate Knowledge of Tester

Internal rusting

Lack of contact on seating

surface (Blue match)

High hardness in Stem

material.

Contamination in DM

Water

In correct disc machining

& machine accuracy.

Body /disc - Poor

Machining & lapping

process

Damage in seat sealing

interface

Excess torque during

operation

Improper movement of valves

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3.3 Significant Causes –Seat Leak

S No CAUSES SIGNIFICANT / IN-

SIGNIFICANT

1 Inadequate Knowledge of Tester & Assembler

INSIGNIFICANT

2 In correct disc machining & machine accuracy INSIGNIFICANT

3 Lack of contact on seating surface (Blue match) INSIGNIFICANT

4 Excess Torque during operation

INSIGNIFICANT

5 Internal rusting INSIGNIFICANT

6 Body /Disc - Poor Machining & lapping INSIGNIFICANT

7 High hardness in Stem material.

INSIGNIFICANT

8 Contamination in DM water INSIGNIFICANT

9 Damage in seat sealing interface

INSIGNIFICANT

10 Improper movement of valve SIGNIFICANT

3.4 Why-Why Analysis

Significant Cause (Valve struck during operation)

Why? Improper movement of valves

Why? Improper handling at site lead to Stem bend,stem broken, Seat

damages, Internal coating peel off.

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Root Cause:

During valve operation during installation, even though the valve accepted during site testing there is a functional issue during open/close which could had happened due to mishandling of valve which results in stem bend & stem broken and Valve

disc seat damage and guide rib damage & coating peel off.

6.0 Conclusion:

Based on the observations, we find the wrong handling method of valve at site lead

to Stem bend and Broken and also damages to the disc seating face and guide rib

damage. Also there is internal coating damage.

7.0 Corrective actions at site

Awareness to be given to site team for proper handing and proper preservation of the valves.

= = End of Report = =