b ball trunnion.pdf

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PT. ALFA VALVES INDONESIAJL. Mercedes No. 324, Wanaherang, Gunung Putri, Bogor - Indonesia

Phone : (62 - 21) 8686 0009 ; Fax : (62 - 21) 8686 0008 Phone : (62 - 21) 8686 0009 ; Fax : (62 - 21) 8686 0008 E-mail : [email protected]

PRODUCTION FLOW CHART of TRUNNION BALL VALVE

AVI-P-FC-001A

0

:

Revision No. :

Document No.

S. Martahan Panjaitan

Tunggul H.P

Approved By :

Prepared By :

pp y

Issued Date : April 08, 2003

This document and it's content are property of PT. ALFA VALVES INDONESIA. Neither this document nor this its content maybe copied in a whole or in apart thereof or transferred to a third party or used in any other way detrimental to the interest ofPT. ALFA VALVES INDONESIA.

Notice

ALFA VALVES DOC NO.

REV.

AVI-P-FC-001A

0 2 OF 6

DATE OF ISSUED

PAGE

8-Apr-03

PRODUCTION PROCESS FLOW CHART OF TRUNNION BALL VALVE

#-

materials againts packing list or suppliersupplier D/D / invoice to Alfa. PO.Discrepancies shall be identifed

DOCUMENT REMARK

Check for correct content and quantityStore Personel

PROCESS

START

INCOMING MATERIAL

PURCASE ORDER VENDOR PACKING LIST

MATERIALS RECEIVE RETURN'S OUTWARD

-

-

-

#-

- Visual Surface Inspection(MSS-SP 55)Di i l I ti

by QC Department.Material Mill Test Reports will be kept

Discrepancies shall be identifedfor remedial actionMaterial stock status raisedfor Direct Material recordMaterials consumable log bookraised for Indirect Material record

QC inspector

DELIVERY MATERIALS CONS. LOG

MATERIALS STOCK

MILL TEST REPORT QC INCOMING

INCOMING MATERIAL

QC INCOMING

INSPECTION-

#

#-

* Height, Handwheel* Etc.

* Wall thicknessDimensional Inspection

meeting receive reports & decidematerial status

NO

* Face to Face/End to End Dimensions

NCMR ( Non Conforming Material

MRB ( Material Review Board)

* Flange Dimensions

NCMR NC TagOK ? NON-CONFORMANCE

YES

-

#

#-

Production Assembly OperatorProduction Work Order shall based on

Report )NC Tag ( Non Conforming Tag )

Store Personel

Sales Order and / or customer delivery

RAW MATERIAL STORAGE

MATERIAL STOCK INVENTORY STOCK

PRODUCTION PRODUCTION WORK COLLECT KIT VALVES

#-

#

parts

Production Assembly OperatorInspect for Quantity and suitability of

Sales Order and / or customer delivery order

Production Assembly OperatorNO

MAT. REQ. / ISSUED ASSY

REQUEST FOR KIT COMPLETENESS

PARTS INS. BEFORE

ASSEMBLY

OK ? MAT. REQ. / ISSUED

#

# MRB

Production Assembly Operator

NO NO

YES

ASSY IN-PROCESS INSTALL BODY SEAT (1) & CAP SEAT(2) INTO

SEAT RETAINER

TRIAL & NCP NCMROK ? OK ?-

#

NCP : Non-Conformance Procedure

Production Assembly OperatorYES

YES

ERROR NCP NCMR

INSTALL SPRING (WAVE OR COIL) INTO

SEAT RETAINER

A

OK ? OK ?

ASSY IN-PROCESS

AVI-P-FC-001A

ALFA VALVES DOC NO.

REV.

DATE OF ISSUED

PAGE

8-Apr-03AVI-P-FC-001A

0 3 OF 6


#

#

MRB


PROCESS DOCUMENT

YES

YES

REMARK

NO NONCMR

A

OK ? TRIAL & ERROR OK ? NCP

#

#

#

MRB

P d ti A bl O t


YESYES

NO NO

INSTALL BODY SEAT

RETAINER (1) ASSY INTO

BODY


ASSY IN-PROCESS

NCMR

#

#

#


MRBNO NO

YES

YESYES


INSTALL BODY SEAT

O-RING


INSTALL

NCMR

ASSY IN-PROCESS

ASSY IN-PROCESS

#

#

MRB

YESProduction Assembly Operator

NO NO

YES

INSTALL BALL INTO

BODY


INSTALL O-RING

NCMR

ASSY IN PROCESS

ASSY IN-PROCESS

#

#

NO NO

YES

YES

MRB


RING, BEARING

INTO LOWER STEM

OK ? TRIAL & ERROR OK ? NCP NCMR

#

#

#

NO

YES

YES Production Assembly Operator


MRBNO

INSTALL LOWER

STEM ASSY INTO BALL


ASSY IN-PROCESS

YESINSTALL THRUST

BEARING & THRUST WASHER

INTO LOWER STEM

B

ASSY IN-PROCESS

AVI-P-FC-001A



0 4 OF 6ALFA VALVES DOC NO.

REV.

DATE OF ISSUED

PAGE

#

#

NO NO

PROCESS DOCUMENT

YES

YES

REMARK


MRB

NCMR

B


#

#

YES

YES



BOLTING LOWER

COVER INTO BODY WITH

STUD BOLTS & NUTS

ASSY IN-PROCESS

INSTALL BEARING,

ASSY IN-PROCESS

#NO NO

YESYES

MRB

,THRUST

WASHER & O-RING INTO UPPER STEM


#

#

#YES


NO NO

YESProduction Assembly Operator

MRB

INSTALL UPPER STEM

ASSY INTO BALL


NCMR

ASSY IN-PROCESS

#

#


YES

NO NOMRB

BOLTING GLAND ASSY INTO BODY WITH HEX

HEAD BOLTS


ASSY IN-PROCESS

#

# MRBNO

YES

NO

YES

Production Assembly OperatorINSTALL

SEAT O-RING INTO CAP


ASSY IN-PROCESS

#YES Production Assembly OperatorINSTALL

GASKET & O-RING

BETWEEN BODY AND

CAP

C

ASSY IN-PROCESS

AVI-P-FC-001A

ALFA VALVES DOC NO.

REV.

DATE OF ISSUED

PAGE0


5 OF 6


#

PROCESS DOCUMENT REMARK


C

BOLTING CAP ASSY INTO BODY ASSY WITH

# Production Assembly Operator

ASSY WITH STUD BOLTS

& NUTS

INSTALL SEALANT

FITTING INTO BODY & CAP

ASSY IN-PROCESS

#

#

NO NO

YESYES

MRB



INSTALL DRAIN PLUG INTO BODY

NCMR

ASSY IN-PROCESS

#

#

MRB

YES

NONO

YES



INSTALL STEM KEY INTO STEM

NCMR

ASSY IN-PROCESS

#

#-

MRBNO

Production Assembly OperatorFor Lever Operator Ball Valves to

NO

Install Lever into Ball Valve :YES


BOLTING GEAR

OPERATOR

ASSY IN-PROCESS

#-

Production Assembly Operator Functional Inspection

* Install Stopper & Snap ring into Lever* Install Lever Assy into Body* Bolting Lever with Set Screw

ASSEMBLY DAILY PERFORMANCE REPORTVALVE ASSY

INSPECTION

OPERATOR ASSY INTO

VALVE MOUNTING PAD WITH HEX HEAD

BOLTS

-

#

YES

NO

Joint torques Inspection

NOMRB

YES

OK ? TRIAL & ERROR

OK ? NCP

D

INSPECTION

NCMR

AVI-P-FC-001A

ALFA VALVES DOC NO.

REV.

DATE OF ISSUED

PAGE


0 6 OF 6


#--

REMARKPROCESS DOCUMENT

Production Testing OperatorShell TestLow-Pressure Closure TestHigh-Pressure Closure Test

D

VALVE PRESSURE

TESTING DAILY PERFORMANCE REPORT

--

#

#

API 598 or API 6D(Upon Customer's Requirements)

YES

NOMRB

Production Painting Operator

High-Pressure Closure Test

COATINGCOATING DAILY

PERFORMANCE REPORT

TESTING

NON-CONFORMANCE OK ? NCMR NC Tag

#-

#-

The Plates are mounted in the mostpracticable position

Production Packing Operator

QC InspectorProduction will advise QC that valves

INSTALL ID PLATE

COATING

FINAL

PERFORMANCE REPORT

REQUEST for QC QC FINAL INSPECTION

#

#

are ready for final Inspection byCompleting a"Request for QC Inspection Form"

NO

YES


QC Inspector

OK ?

FINAL INSPECTION

NON-CONFORMANCE

QC FINAL INSPECTION

NCMR CORRECTIVE ACTION

#

#---

MTR=Material Test Report

DVIR=Dimensions & Visual Ins Report

QC Inspector

PTR=Pressure Test Report

COC=Certificate of Compliance & Test


PACKAGING & DESPATCH

DOCUMENTATION

SALES ORDER

ALFA PACKING LIST

PACKING LABEL

COC MTR

PTR DVIR

-

# Store Personel

DVIR=Dimensions & Visual Ins. Report

SHIPMENT

SHIPMENT SCHEDULE DELIVERY DOCKET

VALVES STOCK INVENTORY STOCK

WARRANTY VALVES DATA LOG

END

AVI-P-FC-001A

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