Minutes of meeting held between L&T Valves Ltd. (LTVL) L&T Hydrocarbon Engineering Limited (LTHE) at Cairn MPT (Mangala Processing Terminal) Barmer site on 09.01.2016.
Member Presents: -
M/S LTHE M/s L&T Valves Ltd.
R. B. Sharma Vikash Kulshrestha
Sridhar Lakshminarayanan H
Sainath Balasubramanian M
P. Mandal Syed Imran
Sriram Rao Diwakar Nandan
M/s LTVL representatives visited Cairn MPT Barmer site from 30.11.2015 to 09.01.2016 to attend the complaint of valvesreported for not operating/Jamming. Following are the observations: - LTVL OBSERVATION
1. 02 nos. 36”#150 MPT-XSV-2642 sr. 14G70115 and 2542sr. 14G70116 with Rotex Pneumatic Actuators:-
A. 1 Nos. 36”#150 Tag. No.: MPT-XSV-2642:-
a. Valve Stem was removed on-line without dismantling the valve and observed scoring marks/foreign particles on Bearings.
b. Scoring marks/sharp edges were removed & machining of stem at bearing portion to remove high points was carried out. Assembly completed with new bearings.
c. Valve operation was checked after stem assembly and found operating smoothly in manual as well as pneumatically with actuator.
B. 1 Nos. 36”#150 Tag. No.: MPT-XSV-2542:-
a. Valve was taken out from the line and dismantled, Heavy scoring marks/Foreign particles were observed on all bearings.
b. Scoring marks/sharp edges were removed & machining of bearing block and stem at bearing portion to remove high points was carried out. Valve assembly completed with new bearings.
c. Valve operation was checked after assembly and found operating smoothly in manual as well as with pneumatically actuator.
d. Hydro & pneumatic seat testing of valve carried out and observed no pressure drop/zero leakage.
2. 4 Nos. 20”#150 MPT-MOV-470A0 sr. 15G700201, 470B0 sr. 15G700202, 470C0 sr. 15G700204 and 470D0 sr. 15G700203 with Limitorque Electrical Actuators :-
A. 3 Nos. 20”#150 Tag. No.: MPT-MOV-470A0,470B0 and 470C0:-
a. Valves were taken out from the line and dismantled, Heavy scoring marks/Foreign particles were observed on all bearings.
b. Scoring marks/sharp edges were removed & machining of bearing block and stem at bearing portion to remove high points was carried out. Assembly completed with new bearings.
c. Valves operation was checked after assembly and found operating smoothly in manual as well as electrically with actuator.
d. Hydro testing of valves carried out and observed no pressure drop/zero leakage.
B. 1 Nos. 20”#150 Tag. No.: MPT-MOV-470D0:-
a. Valve Stem was removed on-line without dismantling the valves and observed scoring marks/foreign particles on Bearings.
b. Scoring marks/sharp edges were removed & machining of stem at bearing portion to remove high points was carried out. Assembly completed with new bearings.
c. Valve operation was checked after stem assembly and found operating smoothly in manual as well as electrically with actuator.
3. Open/Close operation of all 37 nos. of Valves (TMBV) as per attached annexure-I was checked and found operating smoothly in manual as well as with actuators.
LTVL requested LTHE to take precautions to avoid foreign particles by proper flushing and cleaning by suitable clear fluid with corrosion inhibitors to ensure satisfactory performance of valves. Pipe line photographs ofdownstream side of valve tag. No.: MPT-XSV-2542 are hereunder, which are self-explanatory. Accumulation of solid (2-3 mm size) foreign particles, heavy rust along with grit (Copper slag) was noticed inside the pipe line which may cause same problem also in other valves installed in the pipe line. Heavy rust observed in the pipe line also accumulating inside the valve internals & affecting performance:-
4. LTVL requested to LTHE to return the old seat rings-02 nos. (presently kept in wooden case) & balance unused spares (Bearings, ‘O’rings & thrust washer) to LTVL Coimbatore plant with safe packing to avoid any damages in transit.
Observations from LTHE:
1. Upon opening of the valves at sitewe found all the bearing blocks were in rusted condition andmost of the valve gear box was found to be corroded. In XSV 2542 the bearing block almost got seized with the valves and it took 3 hrs for us to remove the bearing block from the ball.
2. Pl. note that the foreign material found is of loose dust and the quantity is also very less.Since all these valves are of the same continuous serial no. we strongly suggest investigating the machining (Dimensional issues) issues.
3. RCA Submitted by LTVL is not acceptable and during our interaction with CIL, they are also in the same apprehension and will not accept this RCA. M/S LTVL to find out the reason for failure of the valves and submit the RCA immediately and Requested M/S LTVL to depute a Quality representative to have a discussion with Customer.
4. XSV-2542 & 2642: The observed opening time 40-43 seconds at air pressure of 6.2 kg/cm2 and fail to close time observed 16-17 second.
5. All the 4movs (470 A0, B0, C0 & D0) we found that the current taken by the valve is on higher side (1.5amps instead of 1.24 amps) which is more than prescribed in datasheet. Limitorque has given undertaking that motor will withstand up to 2amps and there won’t be any performance issues.
M/S LTHE M/s LTVL