Download - Valve Deficiency Study :End User Experience
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Valve Deficiency Study :End User Experience
Meshari Al-Otaibi
Aramco Chief Representative, Italy
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• Promote awareness of Saudi Aramco Valve Inspection Requirements & Equipment Deficiency Report concept among procured material's stakeholders
• Improve the quality of supplied valves to Saudi Aramco’s projects and operating facilities in order to mitigate the risk of failure and minimize the associated cost and time impact
Objective
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• Aramco Overseas Company Overview
• Valve Inspection Requirements
• What is the Equipment Deficiency Report?
• Statistics and analysis
• Examples of Defected Valves
• Aramco Support for valve manufacturers
Outlines
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Aramco Overseas Company Overview
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Aramco Overseas Mission:
“To support the Saudi Aramco enterprise by providing optimal services and maximizing value”
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QMD vision
Globally leading partner to Saudi Aramco throughexcellence service provisions
Fully compliant equipment delivered to Saudi Aramco(Zero Defects)
QMD Goal
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Global Presence
Aramco
Asia
Tokyo
Saudi Aramco
Dhahran
Aramco Services
Houston
Aramco
Overseas
The Hague
Milan
Delhi
South
Korea
Singapor
e
Shanghai
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Figures & Facts
Business Volume per Country
IT40%
DE16%
GB11%
FR7%
ES5%
NL5%
BE4%
RO3%
Others9%
Top 5 Manufacturing Countries
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Figures & Facts
Materials Purchased in ItalyMaterial Purchased in Europe
Elec Eq8%
Instr.3%OCTG
6%
Others13%
Pipe, Fitting
and Flange15%
Pumps3%
PV & HX19%
Valves31%
Compr2%
Elec Eq6%
OCTG1%Others
5%Pipe,
Flanges and
Fitting14%
Pumps2%
PV & HX23%
Valves46%
Compr3%
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Valves Inspection Requirements
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Valves Inspection Requirements
ScopeReview and approval of manufacturer’s quality documents
Main Activities• Pre Inspection meeting
(PIM)• Review of Material
Certification, Welding & NDT Requirements
Pre-FabricationIn-process
inspection & testFinal Inspection
& test
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Scope Verification of intermediate manufacturing processes
Main Activities• PMI• Visual inspection
(Castings & Forgings) • NDT Testing (RT, PT MT
or UT)
Pre-FabricationIn-process
inspection & testFinal Inspection
& test
Note: For RT, PT MT , it’s sampling requirements as per specif ication
Valves Inspection Requirements
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ScopeVerification finished product before shipment
Main Activities• Final Visual inspection• Pressure testing • Final painting• Marking &
preparation before shipment
Pre-FabricationIn-process
inspection & testFinal Inspection
& test
Valves Inspection Requirements
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What is Equipment Deficiency Report?
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Definition
Equipment Deficiency Report (EDR) is SAP report established in end of
2001,documenting purchased inspectable material received at site and found
deficient due to manufacturing or transportation problem
Objective
To take effective corrective action & to ensure that reporting, investigation,
and documentation of equipment deficiencies are handled consistently (SAEP-
380 :Equipment Deficiency Report)
What is Equipment Deficiency Report (EDR) ?
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Scope
Purchased Inspectable material:
a. Arrived at site with deficiency(ies).
b. Failed prematurely after being put in service.
Advantages of Equipment Deficiency Report:
a. Report manufacturing deficiencies
b. Identify root cause(s)
c. Determine & implement corrective actions to avoid reoccurrence. d. Measure and evaluate the effectiveness of the quality management
system (manufacturers, inspection agency)
e. identify continual improvement of the quality management system
What is Equipment Deficiency Report?
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Equipment
Deficiency
Report
Initiation
Investigation & remedial
actions
Completion
• Originator Initiate EDR
• EDR coordinator review / assign task to QME
• QME investigation
• Corrective actions
• Evaluate vendor/escalate issue
• feedback reviewed by EDR coordinator
• EDR will be closed
• Interested parties are notified
Defected material
Equipment Deficiency Report Process
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EDR Statistics and Analysis
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Data Collection
22%
21%
15%
14%
7%
5%
4%3%
9%
VALVES
PIPING
ELECTRICAL
STATIC EQUIP.
ROTATING
COATING
• All collected data retrieved from EDRs
between 2007 to 2018
• Valve represent 22 % of total EDRs
OTHER*:structural steel, constructions, gaskets, HVAC, cranes
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Ball
46%
Gate
25%
Check
11%
Plug
6%
Fire Water
3%
Glob…
Butterfly
2%
Control
2%
Choke
0%
Relief
1%
EDR per Valve Types (Manufacturer Responsibility)
Valve EDR Statistics (2007-2018)
• EDR Distribution is aligned with supply
distribution where Ball Valves cover most of supply of this commodity.
• Proportion of defective valves is higher in
large sizes (NPS above 20) sizes against the
number of supplied.
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27%
18%
16%8%
5%
5%
5%
5%3%
3%2% 2% 1%
Body Leaks Seat LeaksCorrosion/Water Residual Coating DefectsVisual/Dimensional Surface Casting DefectsIncorrect Materials Actuator IssuesWelding Defects Marking
Valve defect types (Manufacturer Responsibility)
Valve EDR Statistics (2007-2018)
Valve EDRs attributed to Manufacturer’s
responsibility are due to:
• Improper Assembling / Manufacturing
Procedure
• Improper Internal Inspection Process
• Improper Design
• Improper Sub Supplier Control
• Improper Draining and preservation Procedure
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Pareto Analysis of Root Causes assessed on defective Valves (Manufacturer Responsibility)
Valve EDR Statistics (2007-2018)
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Gaps Analysis & Recommendations
1. Unsatisfactory Vendor Manufacturing and Quality Control Processes performance
• Introduce Statistical approach for Quality Control Processes (e.g. by using new
statistics as p.p.m (part per million) for defective components or delivered defective
valves)
2. Inconsistent approach among Vendors to qualify and manage sub-suppliers (Casting, W.O. and
coating)
• Implement guidelines for sub supplier qualification ( e.g. enforce the use API 20A for
casting sub supplier qualification)
• Formalize processes to ensure sub supplier list are continually monitored and evaluated
3. Design and product validation not properly implemented by Vendor or not mandated by
applicable Specs
• Impose valve qualification tests for critical and or specific applications including
pressure cycles, mechanical quality, tension, bending and thermal.
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The below actions to be taken at Manufacturer’s shop before shipment :
1. Verify the tightness of safety cap or bleed plug screw. This shall be done by
qualified inspector.
2. Ensure that the bonnet nuts are tightened properly by measuring the bolting
tightness torque. Inspector shall check tightness torque against approved Drawings /
Data Sheets.
3. Check the correct lubrication of bearings, operator and seats. Visual inspection shall
be done by qualified inspector to ensure sufficient and correct lubrication is applied
on bearings, operator and seats.
4. Check the Valves correct draining and drying after Hydrostatic Pressure Testing. This
shall be done in accordance with applicable SAMSS and API Standards
Recommendations before valves’ shipment
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Examples of Valve Defects
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Valve external leakages from body sealing
Example
Leakages from body sealing found during on-site tests
Root Cause
Non-adequate assembly technique which compromised the
integrity of gaskets
Corrective Actions
1. Emphasize the importance on proper handling of gaskets
and protection of critical sealing areas by a clear Work
Instructions which shall be available in the Work Shop.
2. Cleanliness of the work area to prevent risk of Foreign
Object Debris during the final assembly.
3. Periodical training course for assembly technique.
Fabrication / Assembly Defects
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Valve external leakages from body sealing
Fabrication / Assembly Defects
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Failure to follow Company Standards/Customer
Requirements
Example:
The manufacture extended the internal FBE coating on
flange raised face (serration area) seating area in
violation to SAES-H-002, Para 5.2.9
Root Cause:
Wrong “interpretation” to the standard requirements
Corrective Actions:
1. Emphasize the importance to “Determine” and
“Review” the requirements for products by ensuring
that all the applicable Standards are available in last
up-dated edition and followed during the entire
realization/manufacturing process.
2. Importance of communication with customer to
obtain feedback, including eventual clarifications.
Design / Engineering / Manufacturing
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Defects on valve components
Example:
Leakages from casted body valve. Casting impurities
classified as unacceptable identified during the
following specific radiographic examination
Root Cause:
Defects on material / valve components not identified
during the inspection stages (visual, NDT, and final
inspections)
Corrective Actions:
1. Implementation of monitoring and measurement
activities at appropriate stages.
2. Validation and periodic revalidation of the
processes.
3. Inspection on sub-contracted activities.
Inspection and NDE Defects
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Aramco Support for Valve Manufacturers
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AOC Support for Valve Manufacturers
• Conducted Valve Manufacturers Symposium in 2017
• Development of lesson learned for valves. Scope of Lesson
Learned is share knowledge, avoid repetition of errors and
ensure highest levels of compliance to the Company and
Industry Standards.
• Conducting PO focus assessment during
manufacturing/assembly.
• Liaison with Saudi Aramco Central Engineering (CSD) &
Vendors to identify opportunities for optimizing and
improving valve specifications
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THANK YOU