FAILURE REPORT @ M/s FLOWSERVE INDIA CONTROL PVT LTD-MMN 1.0 Introduction: M/s BPCL KR placed following orders on M/s Flowserve -Chennai for supply of Piug Valves (including Jacketed valves) :-

(a) A307/0812 : Total Order Qty=710 Nos. Out of same –Qty of Jacketed Plug Valves =097 Nos (all dispatched to site).

(b) A307/1094 : Order Qty=115 Nos. Out of same –Qty of Jacketed Plug Valves =070 Nos (all dispatched to site).

2.0 Discrepancy Reported:

EIL ND reported that the aforementioned supplied Jacketed Valves (097+070 Nos) are not meeting the requirement of API-6D (Short Pattern) w.r.t. Face to Face Dimension. M/s Flowserve supplied above Jacketed Valves with Design Standard as per API-6D(Short Pattern) having Face to Face Dimension as per DIN 3202 Standard which is much larger than compared to requirement of API-6D(Short Pattern). Since aforementioned Jacketed Plug Valves to be installed in jacketed lines at BPCL Site, larger Face to Face dimension valves will be difficult to accommodate and lead to major modifications at site.

3.0 Dispatch Clearance :_

EIL RPOC released, for dispatch, the aforementioned Jacketed Plug Valves based on satisfactory review of relevant inspection documents, submitted by M/s Flowserve after their internal inspection as per ITP enclosed with Purchase Requisition (as EIL inspection of aforementioned size was not required as per ITP) .

M/s Flowserve’s Valve Test Certificates also indicated that the “The jacketed valves are designed & tested as per API 6D (short pattern)”.

4.0 Analysis :

After receipt of aforementioned BPCL orders, M/s Flowserve was submitted relevant drawings reflecting Face to Face dimension as per DIN Std 3202 but same were returned by EIL ND in code “V” stating that drawing approval is not required as same

falls under Category-1. Had these drawings been approved by EIL ND, the reported discrepancy would have been resolved before manufacturing of Jacketed Valves.

M/s Flowserve manufactured the jacketed valves against aforementioned BPCL orders based on their previous experience in MRPL PO No.6993/244 where drawings (API6D Short Pattern with Face to Face dimension as per DIN 3202) were approved by EIL in code-1.

M/s Flowserve is supplying the Jacketed Plug Valves to various domestic and International clients with DIN standard (for Face to Face dimension) due to their design constraint and difficulty to accommodate full jacketing as per API6D(short pattern).

5.0 Action taken by M/s Flowserve: Representative of M/s Flowserve visited at EIL ND (Engg) & expressed their inability to meet stipulated requirement as per PR/API6D(Short Pattern). They requested EIL Engg to accommodate the already supplied jacketed valves in jacketed line at site.

6.0 Conclusion: In our opinion the discrepancy as reported attributed to both M/s Flowserve & EIL.

7.0 Recommendation : Considering feedback received from Jacketed Plug Valve’s manufacturers in India, China and Europe, the Face to Face dimension should be either as per DIN 3202 std or should be one flange size higher so as to accommodate full jacket and good performance. EIL Valve datasheet needs to be changed accordingly.

FULLY JACKETED PLUG VALVE (API 6D -EXTENDED FACE TO FACE)

RPO Chennai Date : 27.06.2015