From: Sent: Tuesday, December 20, 2016 11:22 AM To: Cibi Chakaravarthi K.R Cc: Radhakrishnan G; Shanmugam Ap; Rohith G; Kumaran K; Suriyanarayanan S; Sriram V; Mahalakshmi B; Karthikeyan S; Ravindran G (Ravindran.G@lntvalves.com); Hari K S (Hari.KS@lntvalves.com); M K Baranidharan (barani.mk@lntvalves.com); 'Raja Chacko' (Raja.Chacko@Lntvalves.com); Parthasarathy M S Subject: RE: LT00001775 JPN SVG - 10" 300 Globe valve Returned for Repair / Rework. Attachments: IMG_20161219_151832.jpg Dear Cibi, Yesterday Myself, BM & SURI verified the strip opened parts of the defective valve. The Observations on the strip opened valve as below. 1. The Stellite area of the disc has been eroded : Ref attached Pictures 2. Body Seat area having no damages 3. Actuator not received with the valve Following are the details required for further analysis : 1. The Valve Position in the Pipeline, Line Temperature & Pressure 2. The Valve Sale order No & Line Item ( For checking the actuator availability) After receiving the above Data s, Let us take a call for Reworking of the same disc. Thank you. With Best Regards Rajesh. S Quality Assurance From: Kumaran K Sent: Wednesday, December 14, 2016 2:49 PM To: ; Suriyanarayanan S Cc: Radhakrishnan G; Shanmugam Ap; Rohith G Also, we observed heavy pitting in the disc base material. Rajesh / Suri : Valve tested, striped, components cleaned & kept. Pl. analyze the root cause for failure & to advice the corrective action to be taken by us. Regards KKu From: Rohith G Sent: 14 December, 2016 2:42 PM 1
To: Cc: Radhakrishnan G; Kumaran K; Shanmugam Ap We have tested the valve in the received condition and found to leak. When dismantled and checked, lot of damages was observed on the disc seating face. Pls confirm if any rework was attended at the site by service engineers? Regards Rohith G From: Rohith G Sent: Saturday, October 08, 2016 4:49 PM To: Cc: Radhakrishnan G; Kumaran K; M K Baranidharan; Shanmugam Ap (apa.shanmugam@lntvalves.com); Raja Chacko The valve is received in the below mentioned condition. Gear unit shaft is in dismantled condition. 2
Pls provide the missing items. We are proceeding with testing using new gear unit. Regards Rohith G From: Sent: Saturday, October 08, 2016 1:06 PM To: Shanmugam Ap; Rohith G; Kumaran K Cc: Sriram V; Hari K S; Karthikeyan S; M K Baranidharan; Raja Chacko; Mahalakshmi B; Radhakrishnan G; Ravindran G; Parthasarathy M S; Praveen Arora Importance: High Dear All, Below Defective Valve recd at our Plant on 22.09.2016. Please advise on Dismantling & rectification dates on the below table. Before it Getting Urgent from customer, Let us Complete the Necessary actions at our end S No What When Who How 1 Valve Despatch From Customer End 28.06.2016 09.09.2016 MSP Valve arrived at CBR on 15.09.2016 & reached our premises by today 22.09.2016 2 Dismantle of Valve for Initiate Investigation After Receipt of Valve 11.07.2016 Tentative 19.09.2016 KKU,Rohith,,CR,SR 1. Dismantling of Valve & Initiate Root Cause Analysis 2. Necessary Spares (Disc & Seat ) to be 3
22.09.2016 08.10.2016 3 Rectification Of Valves 15.07.2016 23.09.2016 15.10.2016 5 Despatch of Repaired Valve 25.07.2016 26.09.2016 18.10.2016 KKU, Rohith, Identified & Arranged for Rectification 3. After Dismantling, Disc can be reworked if possible. 1. Complete Cycle Testing to be done for the Valve after Rectific ation With Best Regards Rajesh. S Quality Assurance From: Sent: Thursday, September 22, 2016 5:05 PM To: Shanmugam Ap; Rohith G; Kumaran K Cc: Sriram V; Hari K S; Karthikeyan S; M K Baranidharan; Raja Chacko; Mahalakshmi B; Radhakrishnan G; Ravindran G; Parthasarathy M S; MV Ramana; Praveen Arora Importance: High Dear All, Below Defective Valve recd at our Plant today 22.09.2016. Please advise on Dismantling & rectification dates on the below table. S No What When Who How 1 Valve Despatch From Customer End 28.06.2016 09.09.2016 MSP Valve arrived at CBR on 15.09.2016 & reached our premises by today 22.09.2016 2 Dismantle of Valve for Initiate Investigation After Receipt of Valve 11.07.2016 Tentative 19.09.2016 22.09.2016 3 Rectification Of Valves 15.07.2016 23.09.2016 4 KKU,Rohith,,CR,SR KKU, Rohith, 1. Dismantling of Valve & Initiate Root Cause Analysis 2. Necessary Spares (Disc & Seat ) to be Identified & Arranged for Rectification 3. After Dismantling, Disc can be reworked if possible. 1. Complete Cycle Testing to be done for the
5 Despatch of Repaired Valve 25.07.2016 26.09.2016 Valve after Rectific ation Regards, From: Sent: Saturday, September 17, 2016 10:34 AM To: Shanmugam Ap; Rohith G; Kumaran K Cc: Sriram V; Chandra Murugan C; Hari K S; Karthikeyan S; M K Baranidharan; Raja Chacko; Radhakrishnan G; Ravindran G; Parthasarathy M S; MV Ramana Dear All, Refer below Mail. The Subjected Valve 10 300 Globe is returned by customer for repair & Valves arrived at CBR. Expected to receive at our Plant by today evening. This valve is returned 2 nd time to us & Problem reported is repeated seat Leakage. Attached mail communication from customer for your ref. The Following Activity Plan made for Receipt of Defective Valve, Analysing & Repairing of the Valve The Dates which have been given are Tentative, Request concerned to confirm the dates Please S No What When Who How 1 Valve Despatch From Customer End 28.06.2016 09.09.2016 MSP Valve arrived at CBR & will be reach our premises by today 17.09.2016 evening 2 Dismantle of Valve for Initiate Investigation After Receipt of Valve 11.07.2016 Tentative 19.09.2016 3 Rectification Of Valves 15.07.2016 23.09.2016 5 Despatch of Repaired Valve 25.07.2016 26.09.2016 5 KKU,Rohith,,CR,SR KKU, Rohith, 1. Dismantling of Valve & Initiate Root Cause Analysis 2. Necessary Spares (Disc & Seat ) to be Identified & Arranged for Rectification 3. After Dismantling, Disc can be reworked if possible. 1. Complete Cycle Testing to be done for the Valve after Rectific ation
: I have checked with ARC, Since Consignment booked on to pay basis, we need to arrange for the payment ; Kindly do the needful please. Regards, From: Sent: Tuesday, June 28, 2016 2:23 PM To: Sriram B; Shanmugam Ap; Rohith G; Kumaran K Cc: Sriram V; Chandra Murugan C; Hari K S; Karthikeyan S; M K Baranidharan; Peranandhanathan M; Raja Chacko; Radhakrishnan G; Rangaprasad S; Ravindran G; Parthasarathy M S; MV Ramana Subject: RE: LT00001775 JPN SVG Dear Sriram, Refer Below Mail. As Per your Annexed E mail Regarding, 10 300 Globe Valve is Being returned from Site for Rectification ; Complaint LT00001775 Re opened ; Please Confirm us, once the valve despatched from Site. The Following Activity Plan made for Receipt of Defective Valve, Analysing & Repairing of the Valve S No What When Who How 1 Valve Despatch From Customer End 28.06.2016 B Sriram Follow Up with Customer & Send the despatch LR Details 2 Dismantle of Valve for Initiate Investigation After Receipt of Valve 11.07.2016 Tentative KKU,Rohith,,CR,SR 3 Rectification Of Valves 15.07.2016 KKU, Rohith, 5 Despatch of Repaired Valve 25.07.2016 Thank you. Regards, 1. Dismantling of Valve & Initiate Root Cause Analysis 2. Necessary Spares (Disc & Seat ) to be Identified & Arranged for Rectification 3. After Dismantling, Disc can be reworked if possible. 1. Complete Cycle Testing to be done for the Valve after Rectific ation 6
From: Sent: Thursday, 26 May, 2016 10:31 AM To: MV Ramana Cc: Sriram V; Chandra Murugan C; Hari K S; Karthikeyan S; M K Baranidharan; Peranandhanathan M; Raja Chacko; Rangaprasad S; Ravindran G; Sriram B; Parthasarathy M S Subject: RE: LT00001775 JPN SVG Dear Sir, The particular complaint on 10 300 is Re-opened in Portal on Jan 2016. This is the 3 rd time we are receiving the complaint on the same Valve. A Query raised by our sales in Feb 2016 that Customer selected Wrong Valve in this Case ( Globe Valve instead of Control Valve chosen by customer ) Annexed Mail communication for your ref. At the same time, we have notified by our Service Engineer Mr. B. Sriram that, customer is planning to return the valve to CBR for further analysis. Today, I have again spoken to Sriram to confirm about the returning of defective valve ; On the receipt of the same, we will analyse along with the design. Background : Complained Valve : 10"300 Globe Valve Valve SI No SI No : C901316 1 st time Complaint booked in Portal LT00000900 Dt 20 Feb 2014 Complaint Description : 10"300 GLOBE WCB T8 BW ACT (MOV064) During the course of condensate system Hydro Test, we found the leakage from valve seat of this valve. Leakage happened after pressure crossed 57 Kg/Cm². On 2nd attempt of pressurizing the system, leakage found after 46 Kg/Cm² Action Taken : Actuator and gear unit were changed in LTVL. Hydro witness inspection carried out and found satisfactory. Valve despatched on 14th may 2014 through ARC transport, LR details:s-755750. 2 nd time Complaint booked in Portal LT000017775 Jun 2015 Complaint Description : 10 300 Globe Valve Repeated Seat Leakage Action Taken : Gasket & Gland Packing supplied on 20 Jun 2015. 3 rd time Complaint Re opened in Portal LT000017775 Jan 2016 Complaint Description : 7
10 300 Globe Valve Repeated Seat Leakage Action Taken : Design has Reviewed the sizing again. The actuator is adequately sized. Even for the seat test pressure of 62 bar (beyond Class test pressures), there is a margin of 30%. For the design pressure of 42 bar, there is a margin of 50%. Found Ok Regards, -----Original Message----- From: MV Ramana Sent: Tuesday, 24 May, 2016 12:16 PM To: Rangaprasad S Cc: Sriram V; Chandra Murugan C; Gunasekaran M; Hari K S; Karthikeyan S; M K Baranidharan; Peranandhanathan M; Raja Chacko; ; Ravindran G Subject: RE: LT00001775 JPN SVG VSM When are we closing this complaint - I am told that it is a wrong selection of Globe Valve? MVR -----Original Message----- From: MV Ramana Sent: Monday, March 7, 2016 3:52 PM To: Rangaprasad S Cc: Sriram V; Chandra Murugan C; Gunasekaran M; Hari K S; Karthikeyan S; M K Baranidharan; Peranandhanathan M; Raja Chacko; ; Ravindran G Subject: LT00001775 JPN SVG SRP What is the resolution of these complaints: Seat leakage issue - 1. 10"300 GLOBE WCB T8 BW ACT (MOV064) 2. 10"150 GATE WCB T8 BW ACT(MOV04), 3. - 10"150 GATE WCB T8 BW ACT, 4. 10"300 GLOBE WCB T8 BW ACT Thanks/ MVR 8