COMPANY PROFILE. BROSCO VALVES PVT. LTD. (EnC Division)

Transcription

1 COMPANY PROFILE BROSCO VALVES PVT. LTD. (EnC Division) Registered Office Address: Plot No 1/4, 3 rd Floor,Chandroday CHS, opp Swastik Chamber, Chembur (East), Mumbai Tel-: / broscovalves@gmail.com sales@broscoenc.com Factory & Workshop: Plot No. R-339 Part, TTC Ind. Area, Rabale MIDC, Navi Mumbai Tel-: /

2 BRIEF INTRODUCTION OF COMPANY BROSCO is leading manufacturers and supplier of the industrial valves located In NAVI MUMBAI INDIA. We have professional experience of 12 years in valve Industry. At BROSCO we take great pride in meeting your industrial valve requirements, promptly and efficiently. We make valves to exacting specifications with utmost care and quality components. Through continuous process of our products refinement and development, we have enhanced our product Range, which is listed below. A) CAST VALVES RATING GATE VALVE GLOBE VALVE SWING CHECK BALL VALVE CLASS TO 30 2 TO 18 2 TO TO 16 CLASS TO 24 2 TO 16 2 TO TO 12 CLASS TO 16 2 TO 10 2 TO TO 10 B) FORGED VALVES GATE VALVE, GLOBE VALVE, LIFT CHECK VALVE CLASS 800, 900, 1500, 2500, 0.25 TO 2 MATERIAL OF CONSTRUCTION: CAST: ASTM A 216 Gr WCB, WCC, ASTM A 217 Gr WC6, WC1, WC9 ETC ASTM A 351 Gr CF8, CF8M, CF3, CF3M, CF8C, ETC. FORGED STEEL: ASTM A 105, ASTM 182 Gr F304, F316, F304L, F316L, ETC. BROSCO is managed by a team of qualified personnel with extensive experience in Valve manufacturing for both up stream and downstream Oil & Gas sectors in India. Since its inception, BROSCO has created its own quality standards employing strict specifications at each stage of product development & manufacturing ensuring that every component is precise and reliable. Order for the standard range or ask for tailor-made & import substitute with special Requirements. Whether it is a well planned project installation or contingent maintenance replacement, we at BROSCO are geared up to our customers exacting requirements. BROSCO aims at consistent quality and total customer satisfaction through rigid Inspection, at BROSCO you don t have to pay a premium for quality.

3 ENCLOSURES 1. Company Profile Annexure I 2. Organization Chart Annexure II 3. Quality Policy / Systems control Quality Annexure III Assurance program & inspection & Testing Procedures 4. Range of Product with materials Annexure IV 5. Machinery/s installed & personnel s employed Annexure V 6. Source of Raw Material Annexure VI 7. List of our valued clients Annexure VII

4 ANNEXURE I COMPANY PROFILE 1) NAME OF THE FIRM : M/S. BROSCO VALVES PVT. LTD. 2) WORKS & OFFICE : PLOT NO. R-339 PART, TTC INDUSTRIAL AREA, MIDC RABALE, NAVI MUMBAI valves.com -: sales@broscoenc.com 3) TELEPHONE NOS. : , ) FAX NO. : ) CONTACT PERSON : MR JAYAKAR KOTIAN / MR AVINASH POL 7) PLANT AREA : 7000 SQ.FT 8) NEAREST RAILWAY : RABALE STATION 9) NEAREST TRUCK ROAD : EASTERN EXPRESS HIGHWAY LINK 10) NAME OF THE BANKERS : INDIAN OVERSEAS BANK > 11) VAT REGISTER NO. : VAT TIN NO V 12) CST REGISTRATION NO. : CST TIN NO C

5 ANNEXURE II ORGANIZATION CHART DIRECTOR DIRECTOR CHIEF ACCOUNTANT WORKS INCHARGE MARKETING EXECUTIVE ACCOUNTS ACCOUNTS SALES CLERK ASSISTANTS ENGINEER DESIGN PLANNING & QUALITCONTROL PURCHASE ENGINEER PRODUCTION ENGINEER OFFICER STORE WORKMEN KEEPER DISPATCH CLERK

6 ANNEXURE III SYSTEM CONTROL

7 ANNEXURE III INTRODUCTION Our products and associated technology serves the industries that are extremely diverse in their requirements. In particular factors such as Castings acceptance levels vary considerably from one type of use to another. Experience has shown that it is not viable to develop universal system to meet the varying requirements. In response to this situation we offer open examination of our methods and systems by the user or his appointed representative. This type of examination may be considered by on a single contract basis or as a regular user basis. We do not seek a format approval but in case of any approval implicitly or inherent in our acceptance as suppliers may be endorsed on a format basis by a user if he so wishes. Additionally in case of any variation in our system which may arise in the context of individual contracts, this facility is directed towards intermediate contractors who are themselves endeavoring to meet the diverse requirement of their principles. Except as stated by contractual commitment on such features as flange connection etc. no blanket standards shall be considered to apply however the construction and control of our products are predominately influenced by Indian and API/ANSI/BS/DIN/JIS standards and their various derivatives and supplements. Where references are made to certain standards in the attached summary these indicate our normal practice. Since many standards include sections to be mutually submitted agreed between user and supplier our compliance on any specific requirement.

8 ANNEXURE III A summary of the principal areas and factors relating to the Quality Assurance 1.0 Q.A. SYSTEM 1.1 Q.A. System is continuously updated and supported by mandatory instructions in selected key area such as product design, product selection, purchasing of critical components on line inspection and final inspection. 2.0 TRACEABILITY OF PRODUCT 2.1 Individual Valves carries serial number and it s Test Certificates along with full record of valves. 2.2 Permanent traceability of pressure casting in maintained through foundry, Melt foundry Melt heat number stamped on casting traceability of critical but non cast members during production is maintained through various forms of individual identification. 3.0 WORK ORDER (W.O) Each order is registered under work order (Document Available) valves serial No. is allocated in advance at the time of issuing of work order no. and valve serial no. is given then the key reference around which all further actions are taken. 3.2 The Technical specification sheet of each valve is attached to the work order sheet Document Available) to record all detail relating to the selection of the valve for the specific application, i.e. process conditions. 3.3 Additionally any specific requirement indicated is taken into account and is reflected on work order sheet.

9 ANNEXURE III 4.1 PURCHASING: All purchasing of materials and components are regulated by work order and stores indent for documentary support and General supervision of supplies is maintained by Q.A Department in conjunction with Purchasing Department. 4.2 We procure raw materials from approved vendors. The distribution of the requirement is depending upon the nature of the materials vendor rating delivery schedule etc. in case of frequency defects rejections of castings Quality Assurance Department request for tech. Development of product or the processing of castings special alloys pouring and testing at the Foundry are witnessed by the Quality Control people from time to time to ensure the quality of the castings. 5.0 INSPECTIONS: 5.1 Inspection of incoming goods is important aspect for smooth flow of production all incoming goods shall be offered to Quality Assurance Department for checking the quality, quantity, weight, measures as per the purchase order and to check whether required inspection records and certificate are available along with the consignment and to scrutinize the records and certificates. 5.2 The castings are accepted provisionally subject to final acceptance after machining and hydraulic test (in case of pressure retaining items) we send for supplementary tests like Radiographic, Ultrasonic, Corrosion, Magnetic Particle etc. whenever required to recognizes laboratories. 5.3 All Machined components imported and sub contract components also pass through same level of inspection by Q.C. The levels of inspiration range from sample to 100% based on historical reliability. Each component inspection not allowed upgrading or downgrading of level subject to consistency 5.4 Sub standard or Defective components are rejected reviewed and recorded and remedial action vide Non confirmative Report (Document Available) 5.5 Assembled valve is subject to Final in house test and check procedures and cleared for inspection dispatch end user.

10 ANNEXURE III 6.0 FINAL CLEARANCE 6.1 The quality assurance development put accepted tags / stickers upon satisfactory completion of tests and final finishing and shall finally inspect the product prepared for dispatch keeping in Mind the customers special requirements. 7.0 DESIGN: 7.1 Valve are manufactured accordingly to widely accepted national / international standard or codes viz ANS, IAPI, IS, JIS, DIN etc. The particulars emphasis placed on requirements of ANSI/ASME/API/SIN/API/BS codes and practices being followed for the most recognized references. 7.2 Company s design standard and practices are laid down in the form of technical data sheets. 7.3 New design issues are released only after proper scrutiny. 7.4 Amendments are similarly issued under recorded revisions systems. 8.0 TEST EQUIPMENT CALIBRATION All calibrated test and measuring equipments are subject to routine and recorded checking or Recalibration. Intervals of Examination vary with rate of usage. 9.0 STORAGE 9.1 Storage of all materials is kept inside the factory accommodation. 9.2 Transit packaging various with size of commodity distance and destination. All goods are protected against environmental conditions as minimum AFTER SALES SUPPORT 10.1 Complete product support is available to cover after sales activities installation, commissioning, servicing during plant shutdown and user s training Full historical records of every valve produced and subsequent modifications carried out are maintained by the department On site experience leading to maintenance or improvement in quality is feedback to the Design department Quality Assurance is further supervised by senior personnel at the highest level.

11 ANNEXURE III 1.0 SCOPE: 1.1 The quality plan has been prepared in Tabulation form to describe briefly the typical quality practice activities which are applied for control valves production. This is attached separately and forms a useful guide for quick reference. 2.0 ORDER ENTRY AND REVIEW: 2.1 Each enquiry or order is reviewed by sales engineer. The Engineer is responsible for sizing of the valve using the computer program incorporating design criteria. 2.2 The Engineer checks the complete process parameters and application data reviews the customer s choice of materials and if necessary recommends suitable materials to meet with operating process conditions. 2.3 The Sales Engineer prepares the final updated control valves technical specifications and accordingly the Order acceptance and Work Order sheet are made. 2.4 The Order acceptance sheet and work sheet are once again checked technically and commercially by senior authorized personnel before issued to production department and other concern departments. 3.0 QUALITY ASSURANCE REQUIREMENTS: 3.1 In parallel with the design of valve the quality assurance requirements of the contract are assessed. 3.2 Unless a non standard requirement is communicated each component undergoes a standard system of inspection as per Quality plan. 4.0 PURCHASING CONTROL: 4.1 All critical components i.e. valve internal and pressure retaining parts are purchased from an approved supplier. Source inspection is carried out to ensure that customer requirements are met with. 4.2 All approved suppliers are subjected to regular audits

12 ANNEXURE III 5.0 CONTROL OF MANUFACTURE: 5.1 The manufacture of components is controlled by a system identified by work order number the work order contain all manufacturing information like serial number, description, drawing number date and quality control identification mark. 5.2 All components relating with respect to assembly and final inspection. It is the responsibility of the production department to satisfy quality as per Q.A. plan. Quality Assurance Manger shall approve the test report which will be final binding upon Manufacturing Department. 5.3 Pre assembly checks are done by the shop personnel as the per quality / production plan in line with the details given in the work order. 5.4 Defects are reported to the design department the amendment in the drawings due to process if any are incorporated in co-ordination with manufacturing department. 6.0 NOTES 6.1 Copies of all Test certificate for materials are duly co-related with heat number and are furnished to customer when required. 6.2 IBR Certificates in Form III C are furnished 6.3 All in process records are shown to the inspection agency on demand. 6.4 All instruments and gauges used for testing measurements are duly calibrated at regular intervals. 6.5 All materials are as per technical specification and approved drawings. 7.0 LEGEND PT : Die Penetrate Test MT : Magnetic Particle Test RT : Radiography Test UT : Ultrasonic Test TC : Test Certificate HT : Heat Treatment

13 ANNEXURE III INSPECTION AND TESTING All Brosco Cast Steel Valves are inspected and tested at the factory using written procedures that are in strict compliance with API 598 and API 600 specifications. Inspection and testing of Brosco Cast Steel Valves include as applicable. 1. Visual Examination 2. Hydrostatic Shell test 3. Backseat Test 4. High Pressure Closure Test 5. Low Pressure Closure Test BROSCO Cast steel valves are inspected and tested as follows. 1) VISUAL EXAMINATION (Gate globe and Swing Check Valves) A visual examination is performed on all castings of bodies, bonnets, covers and closure elements in accordance with MSS-SP -55, Quality Standard for Steel Castings and with reference to purchase specifications. 2. HYDROSTATIC SHELL TEST (Gate, Globe and Swing Check Valve) The Purpose of this test is to ensure that the valve shell will withstand pressures up to 1.5 times the Pressure at the 100 degree F rating with no visual leakage or harmful inelastic deformation. a) Frequency of Hydrostatic Shell test 100% on all valves b) Test Media The Test media is water containing a rust inhibitor at a temperature not exceeding 125 degree F. c) Test Pressure The shell test pressure is 1.5 time the pressure rating of the valve at 100 degree F. Rounded of to the next higher increment of 25 psig.

14 VALVE RATING TEST PRESSURE PSIG Class Class Class d) Test Duration VALVE NPS MIN. TEST DURATION (SEC) < / & OVER 300 e) Test Procedures The Shell test is performed by partially opening the valve assuring that all internal surfaces sales and packing are exposed to the test Media and pressure for the proper time duration. f) Acceptance rejection criteria No visible evidence of external leakage for the duration of the test 3) BACKSEAT TEST (Gate and Globe Valves only) The Purpose of the back seat test is to ensure that the stem backseat area will not leak at 1.1 times the pressure rating at 100 degree F. A) Frequency of Backseat Test 100% on all gate and Globe Valves B) Test Media The Test Media in water containing a rust inhibitor at a temperature not exceeding 125 degree F. C) TEST PRESSURE The Backseat test pressure is 1.1 times the pressure rating of the valve at 100 degree F.

15 VALVE RATING TEST PRESSURE (PSIG) Class Class Class D. TEST DURATION VALVE SIZE (NPS) MIN. TEST DURATION (SEC) <2 15 >2 60 E. TEST PROCEDURE: The backseat test is performed by opening the valve completely until it can not be opened. Further by hand, Test Media and pressure are exposed to all internal surfaces including the backseat F. ACCEPTANCE / REJECTION CRITERIA No leakage is allowed through or around the stem packing during the required test duration HIGH PRESSURE CLOSURE TEST: (Required for globe and Swing Check Valves. Optional for Gate valves) The Purpose of the high pressure Closure test is to verify the integrity of the valves seating ability at 1.1 times the maximum allowable pressure at 100 degree F. a) Frequency of High Pressure Closure test. 100% all Globe and Swing Check Valves. High pressure closure test are conducted on Gate Valves only upon Customer request. b) Test Media The Test Media is water containing a rust inhibitor a temperature not exceeding 125 degree F. c) Test Pressure: The High pressure closure is 110% of the maximum pressure at 100 degree F.

16 VALVES RATING TEST PRESSURE Class Class Class d) TEST DURATION VALVE SIZE (NPS) MIN. TEST DURATION (SEC) <2 15 > & OVER 120 e) Test procedure: With the valves in the fully closed position, the seating surface (wedge / seat / or disc / seat) are exposed to the test pressure and media. For gate Valve both seating surfaces are tested. f) Acceptance / Rejection criteria The Maximum permissible leakage rate for check calves is 3 cubic centimeters per inch of nominal pipe size. The allowable leakage rate for gate and Globe Valves are Shown below:- VALVE SIZE (NPS) MAXIMUM ALLOWABLE LEAKAGE DROPS PER MINUTE /CC < / / / & Over 28 /1.75

17 4. LOW PRESSURE CLOSURE TEST: (Required for Gate Valves only, Optional for Globe Valves The Purpose of the Low pressure closure test is to verify the integrity of the valves seat surface at approximately 80 psig. a. Frequency of Low Pressure Closure Test. 100% on all gate valves. b. Test Media The test media is air c. Test Pressure The test pressure is approximately 80 psig d. Test Duration VALVE SIZE (NPS) MIN TEST DURATION (SEC) < / & OVER 120 e. Test Procedure The pressure is applied successively to each side of the closed valve with the other side open to atmosphere. Water is added to the open side to check for leakage. f. Acceptance / Rejection Criteria Acceptance criteria for allowable leakage are: VALVE SIZE (NPS) MAXIMUM ALLOWABLE LEAKAGE <2 0 BUBBLES / MIN. 2.1 / BUBBLES / MIN. 8 / BUBBLES / MIN. 14 & OVER 168 BUBBLES / MIN.

18 BROSCO VALVES INSPECTION AND TESTING: In addition to Brosco factory inspections and tests, Brosco Valves conducted non destructive inspection (visual and hydrostatic pressure test) on incoming Gate, Globe and Swing Check Valves. Inspection and tests conducted by Brosco are in accordance with written procedures that are in strict compliance with API 600.

19 ANNEXURE IV RANGE OF PRODUCTS & MOC A) MATERIAL AVAILABLE ASTM SPECIFICATION i) CAST STEEL A 216 GR. WCB A 217 GR. C5 A 217 GR. WCI A 217 GR. WC6 A 217 GR. WC9 A 351 GR. LCB A 352 GR. LCC ii) CAST STAINLESS STEEL A 351 GR. CF8, CF8C, 321 A 351 GR. CF8M A 351 GR. CF3 A 351 GR. CF3M A 743 GR. CN7 (Alloy 20) A 494 GR. CF. 12M (Hastelloy C) A 351 GR. N 12M (Hastelloy B) MONEL 400 & 500 Duplex Stainless Steel iii) FORGED STEEL 105, F11, F22 LF2 A 182 GR. F 304 A 182 GR. F 316 A 182 GR. 304 L A 182 GR. F 316 L iv) CAST IRON IS 210 GR. Fg 200,220, 260 ASTMA 126 BS 1452 GR. 220 V) DIN Vi) TRIM PARTS 6 13% CR 15 SS 304, SS 316, SS 304L SS 316 L, ALLOY 20 MONEL & STELLITING etc.

20 ANNEXURE IV PRODUCT RANGE A CAST VALVES RATING GATE VALVE GLOBE VALVE SWING CHECK BALL VALVE CLASS TO 30 2 TO 18 2 TO TO 16 CLASS TO 24 2 TO 16 2 TO TO 12 CLASS TO 16 2 TO 10 2 TO TO 10 B FORGED VALVES GATE VALVE, GLOBE VALVE, LIFT CHECK VALVE CLASS 800, 900, 1500, 2500, 0.25 TO 2 PLUG VALV5-BS 5353 SIZE CLASS API 6D NB TO /2 NB TO 8 NB NB TO 6 NB 600 OTHER PRODUCTS ARE NEEDLE VALVES, PRESSURE REDUCING VALVES, STEAM TRAPS SAFETY RELIEF VALVES. FORGED SIZE CLASS ½ NB TO 12 NB 800 CAST 1 NB TO 10 NB /2 NB TO 8 NB NB TO 6 NB 600

21 ANNEXURE V LIST OF THE MACHINERY S INSTALLED S.NO TYPE PO MACHINE DESCRIPTION QTY 1 LATHE MACHINE CENTER HEIGHT CHUCK DIA BED LENGTH 2 26inch 36 inch 12ft 1NO 3 20inch 30inch 10ft 1NO 4 08inch 12inch 08ft 1NO 5 14inch 24inch 8ft 1NO 6 12inch 18inch 8ft 1NO 7 DRILL MACHINE 40MM CAPACITY 1NO 8 32MM CAPACITY 1NO 9 SHAPPING MACHINE 1NO 10 MILLING MACHINE 1NO 11 WELDING MACHINE 1NO 12 TOOL POST GRINDER 2NOS 13 BANDSAW MACHINE 1NO 14 CRANE 3, TON CAPACITY 1NO 15 BENCH VICE 3 NOS 16 VERNIER CALIPER 36 INCH 1NO 17 24INCH 1NO 18 12INCH 4NOS 19 8INCH 2 NOS 20 MICROMETER 0 TO 50 1NO 0 TO 100 1NO

22 21 HYDRAULIC TESTING PUMP 3NOS 22 AIR COMPRESSOR 1 NO 23 TESTIN BENCH 1NO 24 TESTING PLATES UPTO 24 1 SET 25 DRILLING JIG 1 SET 26 DRILL MACHINE 1/2 1 NO 27 CUTTING MACHINE CAPACITY 6 DIA. 1 NO 28 WEIGHING MACHINE 2 NOS 29 BOOSTER PUMP 1 N0