Review 004

TECHNICAL REPORT

Project: Overhauling And Calibration OfControl Valves

Engro Fertilizers Plant-II Shutdown, Dharki(April 27 – May 10, 2016)

Client:

Submitted to: Mr. Asad Naeem (Instrument Engineer)

Work Order Reference: 6636 Purchase Order Reference: 5000001993

Flowtronix Head Office: 101/s, Quaid-e-Azam Industrial Estate, Kot Lakhpat, Lahore 54760 – Pakistan. UAN: 111-355-355 (111-EKL-EKL) Tel: 92-42-35215611 Fax: +92-42-35151104

E-mail: [email protected]

Manpower DetailOrganogramTools & Equipment Used Page 3List of control valvesDaily Progress LogValve Record Sheets

6.1 11-XV-2011A6.2 11-FV-20486.3 11-HV-20116.4 11-XV-2011B6.5 11-FV-20306.6 11-FV-20116.7 11-FV-18016.8 11-FV-20336.9 11-PV-2046

Page 190Page 21

Overhauling and CalibrationsOf Control Valves

6

Table Of Contents12

Page 12

Page 1Page 2

Page 4Page 5

45

3

Page 12Page 13

Page 15Page 16

Page 18Page 17

Page 14

6.9 11-PV-20466.10 11-PV-20276.11 10-LV-10186.12 11-HV-30226.13 11-FV-20266.14 11-FV-20766.15 11-XV-20276.16 11-PV-74986.17 11-PV-2046B6.18 11-PV-71096.19 PIC-611V6.20 LIC-611A6.21 11-FV-70106.22 11-PV-3015B6.23 11-PV-20216.24 11-XV-2027A6.25 11-XV-2027C6.26 11-FV-3021B6.27 11-FV-3026D6.28 11-FV-30226.29 11-LV-5010A6.30 11-HV-10126.31 10-LV-10036.32 11-LV-5010B6.33 10-HV-10086.34 11-TV-3004

Page 20Page 21Page 22Page 23Page 24Page 25Page 26Page 27Page 28Page 29Page 30Page 31Page 32Page 33Page 34Page 35Page 36Page 37Page 38Page 39Page 40Page 41Page 42Page 43

Page 45Page 44

Page 46


Table Of Contents6.37 11-FV-20566.38 10-HV-10096.39 11-LV-3011B6.40 11-LV-3011A6.41 19-FV-9001A6.42 19-FV-90026.43 11-FV-20286.44 11-LV-20556.45 11-TV-54826.46 11-TV-54766.47 11-HV-1032B

Pictures (Work In Progress)

Page 53

7 Page 59

Page 48

Page 58

Page 54Page 55Page 56Page 57

Page 49Page 50Page 51Page 52

1. MANPOWER DETAIL:

Sr. No. Father's Name Trade Shift1 Amer Siddiq Project Incharge Day/Night

2 Mohammad Jamil Supevervisor Day

3 Haq Nawaz Supevervisor Night

4 Sher Muhammad Instr. Fitter Night

5 Abdul Rasheed Instr. Fitter Night

6 M Yameen Instr. Fitter Day

7 M Sadiq Instr. Fitter Day

8 M Ramzan Instr. Fitter Day

9 Basheer Ahmad Instr. Fitter Day

10 M Aslam Instr. Fitter Day

11 Abdul Hameed Instr. Fitter Night

Sagheer ahmad Sajid

M Ilyas

M Tariq

NameRamiz Siddiq

Sajid Tanveer

Sajjad ahmad

Overhauling and Calibrations OfControl Valves

Abdul Rehman

Saeed Ahmad

Jalal Uddin M Akbar

M Shafiq

Aamir Usman

M Khalid

11 Abdul Hameed Instr. Fitter Night

12 Ali Hassan Instr. Fitter Night

13 Riasat Ali Instr Tech Day

14 Maqbool Ahmad Instr Tech Day

15 Ghulam Akbar Instr Tech Day

16 Amman Ullah Instr Tech Day

17 Mohammad Bashir Instr Tech Night

18 Ghulam Hussain Instr Tech Night

19 Mushtaq Ahmad Instr Tech Night

20 Helper Night

21 Abdul Sattar Helper Day

22 Abdul Wahid Helper Day

23 Iftikhar Husain Helper Day

24 M Yousaf Helper Day

25 Mohammad Nazir Helper Night

26 M Alamgir Helper Day

27 Mushtaq Ahmad Helper Night

Mohammad Ali

M Umer

Mohammad Muddasar

Hafiz Adnan Hussain

Mohmmmad Mubasher

Amjad Mubeen

Anees Sattar

M Shoaib

M Zubair

M Adil

Mohammad Umair Riasat

Mohammad Abid Naeem

Abul Sattar

Irfan Ullah

Iftikhar Ahmad

M Shafiq

Aamir Usman

Page 1 of 59

2. ORGANOGRAM:

Day Shift Night Shift

Team 1 Team 2 Team 3

Ramiz Siddiq(Project Incharge)

Mohamad Tariq(Instr. Fitter)

Saeed Ahmad(Instr. Fitter)

Mohammad Ilyas(Instr. Fitter)

M Shoaib(Helper)

Umari Riasat(Instr. Technician)

M Adil(Helper)


Sajid Tanveer(Instrument Supervisor)

Abdul Sattar(Instr. Technician)

Abid Naeem(Instr. Technician)

Irfan Ullah(Instr. Technician)

Abdul Rehman(Instr. Fitter)

Jallal Uddin(Instr. Fitter)

Anees Sattar(Helper)

Team 1 Team 2 Team 3

Mohammad Shafiq(Instr. Fitter)

M Shoaib(Helper)

M Adil(Helper)

Hafiz Adnan(Instr. Technician)

Sajjad Ahmad(Instrument Supervisor)

Amjad Mubeen(Helper)

Mohamamd Ali(Helper)

Sagheer Ahmad(Instr. Fitter)

M Umer(Helper)

Hafiz Iftikhar(Instr. Technician)

M. Muddassar(Helper)

Aamir Usman(Instr. Fitter)

Mohammad Khalid(Instr. Fitter)

Anees Sattar(Helper)

M. Mubasher(Instr. Technician)

Page 2 of 59

3. TOOLS USED:

Screw Drivers (Star Set)

Allen Key Set (Star, mm, inch)

Side Cutters

Monkey Pliers

Combination Pliers

Nose Pliers

Open End & Ring Spanner Sets

Needle File Set

Files (Round, Half Round and Flat)

Stacking Spanner Set (26-50mm)

Hammers (Rubber, Wooden, Brass & MS)


Sr. No. Tools & Equipment

1

2

3

4

5

6

7

8

9

10

11

12

A. Used For Overhauling

Hammers (Rubber, Wooden, Brass & MS)

Lifting Belts & D-Shackles

Vernier Caliper

Digital Multimeter

HART Communicator

mAmp Source

DC Source

Pressure Guage

Air Regulator

5

6

1

2

3

4

B. Used For Calibration

11

12

13

Page 3 of 59

4. LIST OF CONTROL VALVES:Total Quantity : 47 Nos.

6

12-

208--

648

161612

Size (inch)8

12-

1248

11-FV-7010LIC-611APIC-611V

11-PV-2046B1819

11-LV-5010A11-FV-3022

11-LV-3026D11-FV-3021B11-XV-2027C11-XV-2027A

10-HV-1012

10-PV-1021A11-PV-3015B

6

345

789

1011

131415

12

1617

11-TV-300410-HV-100811-LV-5010B10-FV-1003


Sr. No.12

Tag No.11-HV-2071A11-PV-7109

11-HV-1032B4647

-1

444-

11-TV-547645

19-PV-9001A11-FV-202811-LV-205511-TV-5482

42

4443

181888

1010

108-8

12

463

102412

612--88

-

10-HV-100911-FV-205611-PV-1048

11-FV-204811-XV-2011A11-LV-3011A11-LV-3011B19-FV-9002

11-FV-203310-FV-180111-FV-201111-FV-203011-HV-201111-XV-2011B

11-FV-207611-FV-202611-HV-302210-LV-101811-PV-2027

11-PV-2046A

PIC-611V11-PV-2046B

242526

2223

11-PV-749811-XV-2027

18192021

27

36373839

333435

4041

2829303132

Page 4 of 59

5. DAILY PROGRESS LOG:

Sr # Tag No. Activities Date Shift D/NCleaning, Oiling and PolishingFound resetting device faultyFound tyflon inside bodyPnumatic Relay CheckedCalibratedSent for Hydro testingCleaning, Oiling and PolishingFound Valve ball stuckCalibratedSent for Hydro testingCleaning, Oiling and PolishingAir leak test of actuator was found OKHand jack was made smooth by servicingCalibratedSent for HydrotestingCleaning, Oiling and PolishingOverhauling

3 11-HV-2011 27-4-16 Night

Day

4 27-4-16 Night

1 27-4-1611-XV-2011B

2 27-4-16 Day11-XV-2011A

11-FV-2048


OverhaulingCalibratedSent for Hydro testingCleaning, Oiling and PolishingOverhauling StartedCleaning, Oiling and PolishingRemoving & Cleaning PositionerRemoving & Cleaning Limit SwitchesOverhaulingFound leakage in CylinderCleaning, Oiling and PolishingOverhaulingCleaning, Oiling and PolishingOverhauling StartedCleaning, Oiling and PolishingOverhauling StartedCleaning, Oiling and PolishingOverhauling StartedValve body sent for machiningCleaning, Oiling and PolishingOverhaulingCalibratedSent for Hydro testingCleaning, Oiling and PolishingOverhaulingSent Actuator Stem for machiningCalibratedSent for Hydro testing

7 28-4-16 Day10-FV-1801

28-4-16

28-4-16

Day

Day

Night

4 27-4-16 Night

6 28-4-16 Day

5 27-4-16 Night

11-FV-2048

11-FV-2030

11-FV-2011

28-4-16

8

9

10

11-PV-2046B

11-FV-2033

10-LV-1018

Night

Night

11

12

28-4-16

28-4-16

11-PV-2027

11-FV-2030

Page 5 of 59


Sr # Tag No. Activities Date Shift D/N

Day1 27-4-1611-XV-2011B


Cleaning, Oiling and PolishingRemoving & Cleaning of PositionerRemoving & Cleaning of Limit SwitchOverhaulingCalibrationSent for HydrotestingCleaning, Oiling and PolishingOverhaulingCalibrationSent for HydrotestingCleaning, Oiling and PolishingAir Leak test okCalibrationValve Body returned from MachiningCalibrationSent for HydrotestingCleaning, Oiling and Polishing

15 29-4-16 Day

14 29-4-16 Day

13 29-4-16 Day11-FV-2011

11-FV-2033

11-HV-3022

29-4-16 Night16

17

10-LV-1018

29-4-16 Night11-FV-2026

Cleaning, Oiling and PolishingOverhaulingCalibrationSent for HydrotestingCleaning, Oiling and PolishingOverhaulingCalibrationSent for HydrotestingCleaning, Oiling and PolishingAir Leak test okCleaning, Oiling and PolishingOverhauling StartedCleaning, Oiling and PolishingOverhaulingCalibrationSent for HydrotestingCleaning, Oiling and PolishingOverhaulingCalibrationSent for HydrotestingCleaning, Oiling and PolishingOverhaulingCalibrationSent for HydrotestingCleaning, Oiling and PolishingAir leak test okOverhauling Started

19

18

17

29-4-16 Night20

21 30-4-16 Day

Day30-4-1622

23

29-4-16 Night

29-4-16 Night

29-4-16 Night

11-FV-2026

11-FV-2076

11-XV-2027

10-LV-2018

11-PV-7498

11-FV-1801

30-4-16 Day

24 30-4-16 Day

11-PV-2046B

11-PV-7109

Page 6 of 59



Day1 27-4-1611-XV-2011B


Cleaning, Oiling and PolishingAir Leak test okOverhaulingValve Seat Missing, New installedNew Lock relay installedCalibrationSent for HydrotestingCleaning, Oiling and PolishingAir Leak test okOverhaulingCalibrationSent for HydrotestingCleaning, Oiling and PolishingOverhauling StartedCleaning, Oiling and PolishingAir Leak test okOverhauling

Night26 30-4-16

27 30-4-16 Night

25 30-4-16 NightPIC-611V

LIC-611A

11-FV-7010

28 01-5-16 Day11-PV-3015B OverhaulingServicing of hand wheelCalibrationSent for HydrotestingCleaning, Oiling and PolishingAir Leak test okRemoving & Cleaning of PositonerCleaning, Oiling and PolishingAir Leak test okCalibrationSent for HydrotestingCleaning, Oiling and PolishingAir Leak test okCalibrationSent for HydrotestingCleaning, Oiling and PolishingOverhauling StartedCleaning, Oiling and PolishingAir Leak test okOverhaulingFound Leakage in Pneumatic relayFixed Pneumatic realyCalibrationSent for HydrotestingCleaning, Oiling and PolishingAir Leak test okOverhauling Started

29 01-5-16 Day

30 01-5-16 Day

28 01-5-16 Day11-PV-3015B

11-PV-1021A

11-XV-2027A

32 01-5-16 Day

33 01-5-16 Night

31 01-5-16 Day11-XV-2027C

11-PV-7109

11-FV-7010

34 01-5-16 Night11-FV-3021B

Page 7 of 59



Day1 27-4-1611-XV-2011B


Cleaning, Oiling and PolishingAir Leak test okFound valve not 100% openingPositioner DismantledOverhaulingSent body for machiningHydrotest Failed @2400psiBench Set readjustedValve stem readjustedCalibratedSent For HydrotestingCleaning, Oiling and PolishingAir Leak test okCleaning, Oiling and PolishingAir Leak test okSent body for machiningHydrotest Failed

02-05-16 Day

38 02-05-16 Day

39 02-05-16 Night

35 02-05-16 Day

Day02-05-1636

37

11-LV-3026D

10-FV-1801

11-FV-3022

11-LV-5010A

11-FV-7010

Hydrotest FailedFound Valve Positioner faultyFound Pneumatic Relay faultyFixed pneumatic relay and reinstalledCalibratedSent For HydrotestingOverhaulingAir Leak test okSent seat, cage and stem for machiningCalibratedSent For HydrotestingCleaning, Oiling and PolishingAir Leak test okOverhaulingCalibration StartedCleaning, Oiling and PolishingAir Leak test okCalibratedSent For HydrotestingReceived Body from machiningOverhauling

44 10-FV-1003 Cleaning, Oiling and Polishing 03-05-16 DayCleaning, Oiling and PolishingAir Leak test okOverhaulingSent For HydrotestingCleaning, Oiling and PolishingAir Leak test ok

41 02-05-16 Night

39 02-05-16 Night

40 02-05-16 Night

42 03-05-16 Day

43 03-05-16 Day

45 03-05-16 Day

Day03-05-1646

11-LV-3026D

11-LV-5010A

11-LV-5010B

11-FV-7010

11-FV-3021B

11-FV-3022

10-HV-1012

Page 8 of 59



Day1 27-4-1611-XV-2011B


CalibrationSent For HydrotestingCleaning, Oiling and PolishingAir Leak test okSent seat, cage and stem for machining

49 10-HV-1008 Flange Opened 03-05-16 NightCleaning, Oiling and PolishingAir Leak test okSent seat, cage and stem for machiningOverhaulingSent For HydrotestingCleaning, Oiling and PolishingAir Leak test okOverhaulingCalibrationSent For HydrotestingCleaning, Oiling and Polishing

11-TV-300452 04-05-16 Day

48 03-05-16 Night

47 03-05-16 Night

50 04-05-16

04-05-16 Day

Day

51

11-FV-3022

11-PV-7109

11-LV-5010B

10-PV-1021A

Cleaning, Oiling and PolishingAir Leak test okBench Set was foundSent For HydrotestingCleaning, Oiling and PolishingAir Leak test okCalibrationSent For HydrotestingCleaning, Oiling and PolishingAir Leak test okCalibrationSent For HydrotestingCleaning, Oiling and PolishingAir Leak test okCalibrationSent For HydrotestingCleaning, Oiling and PolishingAir Leak test okSeat and plug were sent for machiningAll gaskets replacedDiapharm was found tornedDiapharm replacedCalibratedSent for Hydrotesting

56 05-05-16 Day

11-HV-2071A55 05-05-16 Day

11-TV-300452 04-05-16 Day

54 04-05-16 Night

Night04-05-1653 11-LV-3026D

11-HV-2011A

11-PV-1048

Page 9 of 59



Day1 27-4-1611-XV-2011B


Received seat, cage and stem from machiningSeat gasket replacedBody gaskets replacedAir leak test of actuator was found OKCalibratedSent for Hydro testingCleaning, Oiling and PolishingAir Leak test okPositioner DismantledCleaning, Oiling and PolishingAir Leak test okBench Set was foundCleaning, Oiling and PolishingAir Leak test okOverhauling of body and actuatorSeat and plug were sent for machiningCleaning, Oiling and Polishing

60 06-05-16 Day

06-05-1610-HV-100961 Day

11-PV-710957 05-05-16 Night

11-LV-3011A58 05-05-16 Night

05-05-16 Night11-LV-3011B59

19-FV-9002

Cleaning, Oiling and PolishingAir Leak test okOuter diapharm of actuator was disassembledBench Set was foundCleaning, Oiling and PolishingAir Leak test okPlug, seat and cage were sent for machiningCleaning, Oiling and PolishingAir Leak test okDiapharm was found OkOverhauling of body and actuatorO-rings replacedSeat, plug sent for machiningAll gaskets replacedCalibratedSent For HydrotestingBody gaskets replacedCalibratedSent for Hydro testingReceived Plug, seat and cage from machiningAll three gaskets of valve replacedGland packing was replacedCalibratedSent for Hydro testingReceived Plug, seat and cage from machiningGaskets were replacedGland packing was replaced

67 10-HV-1009 Plug and gland packing were removed 07-05-16 Day

11-LV-3011B65 06-05-16 Night

11-LV-3011A66 06-05-16 Night

19-FV-9001A63 6-5-16 Day

64 06-05-16 Night

06-05-1610-HV-100961 Day

62 06-05-16 Day

19-FV-9002

11-LV-3011B

Page 10 of 59



Day1 27-4-1611-XV-2011B


Received Plug, seat and cage from machiningBench Set readjustedCalibrationSent for Hydro testingCleaning, Oiling and PolishingPlug, seat and cage were sent for machiningTubing was readjustedCalibratedSent for Hydro testingCleaning, Oiling and PolishingAir Leak test okPositioner was removed for cleaningDiapharm was found okCalibratedSent For HydrotestingCleaning, Oiling and PolishingAir Leak test ok

68 11-LV-3011B 07-05-16 Day

10-LV-100772 08-05-16 Day

69 11-HV-1008 07-05-16 Day

11-LV-3011A70 07-05-16 Day

11-PV-749871 08-05-16 Day

Air Leak test okCalibration was tested and found okScratches were found on valve stemRemoved scratches by filing and embre paperAir Leak test okSent For HydrotestingActuator was reopenedOverhauling of body and actuatorCleaning, Oiling and PolishingAir Leak test okCalibrationCleaning, Oiling and PolishingAir Leak test okCalibrationCleaning, Oiling and PolishingAir Leak test okCalibrationCleaning, Oiling and PolishingAir Leak test okCalibrationCleaning, Oiling and PolishingAir Leak test okCalibration

10-LV-100772 08-05-16 Day

73 10-HV-1009 08-05-16 Day

11-TV-547677 10-05-16 Night

78 11-HV-1032B 10-05-16 Night

09-05-16 Day11-FV-202874

11-LV-205575 09-05-16 Night

11-TV-548276 10-05-16 Day

Page 11 of 59

CLIENT DATE: 27-04-2016

PROJECT DOC.NO. CV-E-001

CONTRACTOR JOB NO. F-689

VALVE INFORMATON:

TAG NO: 11-XV-2011A SERVICE: Process Air SIZE: 12"

AREA: AMM-3 FLANGE TYPE: Flanged

PHYSICAL CHECKS:


(Valve Record Sheet)

Engro Fertilizers Limited

Plant-II Shutdown 2016

Flowtronix (Pvt) Ltd.

AIR FAILURE CORRECT

PNEU./ELECT.CONN.CORRECT

PLUG+SEAT MATERIAL CORRECT

PLUG+SEAT SIZE CORRECT

POSITIONER CORRECT

BODY ARROW IN DIRECTION OF FLOW

PROCESS CONN.CORRECT

TEST RESULTS:

CONDITIONS (As Found) & CORRECTIVE MAINTENANCE:

REMARKS:This valve has been overhauled, Calibrated and Cleared for area installation.

Witnessed by Engro Valve Supvervisor : Mr. Allah Baksh

DATE

27-04-2016

EXECUTED BY

Umair Riasat(Instrument Technician)

1. Valve ball was stuck.2. Cleaning, oiling and polishing the vlave ball.

FAIL SAFE ACTION

Close

SUPPLIED PRESSURE

87 psi

VALVE BENCH SET

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 12 of 59




VALVE INFORMATON:

TAG NO: 11-FV-2048 SERVICE: Process Air SIZE: 8-/-4-/-8"

AREA: AMM-3 FLANGE TYPE: RF Flanges

PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

27-04-2016

EXECUTED BY


1. Actuator O-rings were replaced.2. Pug and seat were sent for machining.3. All gaskits were replaced.4. Overhauling5. Calibrated6. Sent for Hydrotesting

VALVE BENCH SET FAIL SAFE ACTION

Close

SUPPLIED PRESSURE

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 13 of 59




VALVE INFORMATON:

TAG NO: 11-HV-2011 SERVICE: Process Air SIZE: 8 "

AREA: AMM-3 FLANGE TYPE: RF 125 AARH

PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Actuator was found stuck.2. Air leak test of actuator was found OK3. Hand jack was made smooth by servicing4. Calibrated5. Sent For Hydrotesting

DATE

27-04-2016

EXECUTED BY


VALVE BENCH SET FAIL SAFE ACTIONSUPPLIED PRESSURE

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 14 of 59




VALVE INFORMATON:

TAG NO: 11-XV-2011B SERVICE: Process Air SIZE:

AREA: AMM-3 FLANGE TYPE:

PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

27-04-2016

EXECUTED BY


1. Tyflon Seat seal was damaged.2. Found air leakage in resetting device.3. Tyflon seat seal replaced.4. Resetting device O-Rings were replaced5. Calibrated6. Sent for hydrotesting


Open

SUPPLIED PRESSURE

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 15 of 59




VALVE INFORMATON:

TAG NO: 11-FV-2030 SERVICE: Process Air SIZE: 10 "


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

27-04-2016

EXECUTED BY


1. Overhauling of actuator and body.2. Actuator Stem was sent for machining.3. Actuator Gasket replaced4. Gland packing replaced.5. Calibration6. Sent for hydrotesting


AIR FAILURE CORRECT




POSITIONER CORRECT



Page 16 of 59




VALVE INFORMATON:


AREA: AMM-3 FLANGE TYPE: RF-125 AARH

PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

28-04-2016

EXECUTED BY


1. Found air leakage in cylinder2. Overhauling of Actuator3. O-rings required relacements, tyflon was wound due to inavailablity.4. Found a embosed spot on piston5. Removing and cleaning of positioner6. Removing and cleaning of Actuator7. Feedback link plate gaskets replaced8. Calibration9. Sent for hydrotesting


Close

SUPPLIED PRESSURE

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 17 of 59




VALVE INFORMATON:



PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

28-04-2016

EXECUTED BY


1. Removing and Cleaning of Positioner2. Overhauling of Actuator3. Plug was sent for machining4. Gland packing replaced5. Seals replaced6. Found a embosed spot on piston.7. Calibrated8. Sent for hydrotesting


AIR FAILURE CORRECT




POSITIONER CORRECT



Page 18 of 59




VALVE INFORMATON:



PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

28-04-2016

EXECUTED BY


1. Overhauling of Actuator2. Overhauling of Body3. Seat seals replaced4. Gland packing replaced5. Vapour Seals replaced6. Actuator O-rings replaced7. Inner and outer plug seals replaced8. Calibrated9. Sent for Hydrotesting


Close

SUPPLIED PRESSURE

30

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 19 of 59




VALVE INFORMATON:

TAG NO: 11-PV-2046A SERVICE: Process Air SIZE: 3 "


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

28-04-2016

EXECUTED BY


1. Overhauling of actuator


Close

SUPPLIED PRESSURE

40

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 20 of 59




VALVE INFORMATON:

TAG NO: 11-PV-2027 SERVICE: Process Air SIZE:


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

28-04-2016

EXECUTED BY


1. Overhauling of Actuator2. Overhauling of Body3. Seat, Plug and cage were sent for machining4. Seat seals replaced5. Gland packing replaced6. Body and seat gasket replaced7. Actuator O-rings replaced


AIR FAILURE CORRECT




POSITIONER CORRECT



Page 21 of 59




VALVE INFORMATON:

TAG NO: 10-LV-1018 SERVICE: Process Air SIZE: 4 "


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

29-04-2016

EXECUTED BY


1. Found Leak test of actuator OK2. Overhauling of Actuator3. Overhauling of Body4. Body was sent for machining5. Seat seals replaced6. Body gasket replaced7. Actuator O-rings replaced8. Gland packings replaced9. Calibrated


AIR FAILURE CORRECT




POSITIONER CORRECT



Page 22 of 59




VALVE INFORMATON:



PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

29-04-2016

EXECUTED BY


1. Air Leak check of actuator was found OK2. Calibrated3. Sent for Hydrotesting


Close

SUPPLIED PRESSURE

60

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 23 of 59




VALVE INFORMATON:



PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

29-04-2016

EXECUTED BY


1. Overhauling of Body2. Overhauling of Actuator3. Seat and plug were sent for machining4. Plug seal ring (carbon) was repalced.5. Inner and outer seals were replaced6. Gland packing replaced7. Calibrated


AIR FAILURE CORRECT




POSITIONER CORRECT



Page 24 of 59




VALVE INFORMATON:


AREA: AMM-3 FLANGE TYPE: RTJ Flanges

PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

29-04-2016

EXECUTED BY


1. Overhauling of body2. Overhauling of actuator3. Inner and outer seals replaced4. Gland packing replaced5. O-rings replaced6. Calibrated


AIR FAILURE CORRECT




POSITIONER CORRECT



Page 25 of 59




VALVE INFORMATON:

TAG NO: 11-XV-2027 SERVICE: Process Air SIZE: 4 "


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

29-04-2016

EXECUTED BY


1. Air leak test of actuator was found OK2. Overhauling of actuator3. Overhauling of body4. Seat, Plug and Cage were machined5. Seat seals replaced4. Gland packing replaced5. Body and seat gaskets replaced6. Calibrated


AIR FAILURE CORRECT




POSITIONER CORRECT



Page 26 of 59




VALVE INFORMATON:

TAG NO: 11-PV-7498 SERVICE: Process Air SIZE: 12 "


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

30-04-2016

EXECUTED BY

Abid Naeem(Instrument Technician)

1. Diapharm was stretched and torn from nut & bolts holes at circumference.2. Overhauling of actuator3. Actuator seals replaced4. Diapharm replaced5. Calibrated


Close

SUPPLIED PRESSURE

58

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 27 of 59




VALVE INFORMATON:

TAG NO: 11-PV-2046B SERVICE: Process Air SIZE: 6-/-3-/-6


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

30-04-2016

EXECUTED BY


1. Overhauling of actuator2. Plug and seat ring polished3. Seat gaskets changed4. Body gaskets replaced5. Gland packing replaced.6. O-rings of actuator replaced.7. Calibrated8. Sent for Hydrotesting


AIR FAILURE CORRECT




POSITIONER CORRECT



Page 28 of 59




VALVE INFORMATON:



PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

30-04-2016

EXECUTED BY


1. Air leak test of actuator was found OK2. Valve bonut was stuck with actuator yoke, heated and hammered to get them separated.3. Overhauling of body4. Plug, Seat and Cage were sent for machining5. Inner and outer body gaskets were replaced6. Both rings of valve plug were replaced7. Calibrated8. Sent for Hydrotesting


Close

SUPPLIED PRESSURE

60

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 29 of 59




VALVE INFORMATON:

TAG NO: PIC-611V SERVICE: Process Air SIZE:


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

30-04-2016

EXECUTED BY


1. Valve seat was not found during disassembly2. Lock relay was not working3. Seat and plug were sent for machining4. Air Leak test of Actuator was found OK5. Overhauling of Valve body6. Seals replaced7. Lock relay replaced8. Calibrated9. Sent for Hydrotesting


AIR FAILURE CORRECT




POSITIONER CORRECT



Page 30 of 59




VALVE INFORMATON:

TAG NO: LIC-611A SERVICE: Process Air SIZE:


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




DATE

30-04-2016

EXECUTED BY


1. Air leak test of actuator was found OK2. Overhauling of Body3. Seals replaced4. Gland packing replaced5. Calibrated6. Sent for Hydrotesting


AIR FAILURE CORRECT




POSITIONER CORRECT



Page 31 of 59




VALVE INFORMATON:



PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Air leakage found in Pneumatic relay of positioner2. Overhauling of Body3. Overhauling of Actuator4. Actuator O-rings replaced5. Body gaskets replaced6. O-rings of pneumatic relay replaced7. Calibrated8. Sent for Hydrotesting

DATE

30-04-2016

EXECUTED BY


FAIL SAFE ACTIONSUPPLIED PRESSUREVALVE BENCH SET

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 32 of 59




VALVE INFORMATON:

TAG NO: 11-PV-3015B SERVICE: Process Air SIZE: 20 "

AREA: AMM-3 FLANGE TYPE: RF-125 AARH

PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Handwheel was found stucking while rotating either way.2. Overhauling of actuator3. Servicing, oiling and cleaning of handwheel4. Calibrated5. Sent for Hydrotesting

DATE

01-05-2016

EXECUTED BY



AIR FAILURE CORRECT




POSITIONER CORRECT



Page 33 of 59




VALVE INFORMATON:

TAG NO: 11-PV-2021A SERVICE: Process Air SIZE:


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Actuator air leak test was found OK.2. Positioner dismantled and cleaned3. Calibrated4. Sent for Hydrotesting

DATE

01-05-2016

EXECUTED BY



Close

SUPPLIED PRESSURE

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 34 of 59




VALVE INFORMATON:

TAG NO: 11-XV-2027A SERVICE: Process Air SIZE: 12 "


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Valve ball was not smoothly opening and closing.2. Air leak test of actuator was found OK3. Polishing, oiling and cleanig of valve ball was done untill required smoothness was aquired.4. Calibrated5. Sent for Hydrotesting

DATE

01-05-2016

EXECUTED BY



Close

SUPPLIED PRESSURE

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 35 of 59




VALVE INFORMATON:

TAG NO: 11-XV-2027C SERVICE: Process Air SIZE: 12 "


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Valve ball was not smoothly opening and closing.2. Air leak test of actuator was found OK3. Polishing, oiling and cleanig of valve ball was done untill required smoothness was aquired.4. Calibrated5. Sent for Hydrotesting

DATE

01-05-2016

EXECUTED BY



Close

SUPPLIED PRESSURE

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 36 of 59




VALVE INFORMATON:

TAG NO: 11-FV-3021B SERVICE: Process Air SIZE: 16 "


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Air leak test of Actuator was found OK2. Overhauling of actuator3. Overhauling of body4. Body seals replaced5. O-rings of actuator Replaced6. Inner and outer body seals were replaced7. Cage seals were replaced8. Gland packing replaced9. Calibration10. Sent for Hydrotesting

DATE

02-05-2016

EXECUTED BY



55

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 37 of 59




VALVE INFORMATON:

TAG NO: 11-LV-3026D SERVICE: Process Air SIZE: 16-/-12-/-16"


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Valve was found not opennig 100%2. Overhauling of body3. Positioner was readjsuted4. Body was sent for machining5. Calibration6. Sent for Hydrotesting

DATE

03-05-2016

EXECUTED BY



AIR FAILURE CORRECT




POSITIONER CORRECT



Page 38 of 59




VALVE INFORMATON:



PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Air Leak test of actuator was found OK2. Overhauling of Actuator3. Overhauling of Body3. Actuator O-rings replaced4. Body gaskets replaced5. Gland packing replaced6. Calibration.7. Sent for Hydrotesting

DATE

03-05-2016

EXECUTED BY

Adnan Hussain(Instrument Technician)


AIR FAILURE CORRECT




POSITIONER CORRECT



Page 39 of 59




VALVE INFORMATON:

TAG NO: 11-LV-5010A SERVICE: Process Air SIZE: 4 "


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Air leak test of actuator was found OK2. Overhauling of body3. Inner and outer body seals replaced.4. Body gaskets replaced5. Plug seals replaced6. Calibrated7. Sent for Hydrotesting

DATE

03-05-2016

EXECUTED BY



Close

SUPPLIED PRESSURE

50

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 40 of 59




VALVE INFORMATON:


AREA: AMM-3 FLANGE TYPE: RF 125 AARH

PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Air leak test of actuator was found OK2. Calibration3. Sent for Hydrotesting

DATE

03-05-2016

EXECUTED BY



Close

SUPPLIED PRESSURE

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 41 of 59




VALVE INFORMATON:



PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Air leak test of actuator was found OK2. Calibration3. Sent for Hydrotesting

DATE

03-05-2016

EXECUTED BY



Open

SUPPLIED PRESSURE

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 42 of 59




VALVE INFORMATON:

TAG NO: 11-LV-5010B SERVICE: Process Air SIZE: 4 "


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Air leak test of actuator was found OK2. Overhauling of body3. Inner and outer body seals were replaced.4. Body gaskets replaced5. Plug seal replaced6. Calibration7. Sent for Hydrotesting

DATE

04-05-2016

EXECUTED BY



Close

SUPPLIED PRESSURE

50

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 43 of 59




VALVE INFORMATON:


AREA: AMM-3 FLANGE TYPE: Lenticular

PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Air leak test of actuator was found OK2. Vlave body stud bolts were jammed with solidified urea3. Seat, plug and cage were sent for machining.4. Calibration5. Sent for Hydrotesting

DATE

04-05-2016

EXECUTED BY



Close

SUPPLIED PRESSURE

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 44 of 59




VALVE INFORMATON:

TAG NO: 11-TV-3004 SERVICE: Process Air SIZE:


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Air leak test of actuator was found OK2. Overhauling3. Valve bench set was found4. Calibration5. Sent for Hydrotesting

DATE

04-05-2016

EXECUTED BY



Close

SUPPLIED PRESSURE

55

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 45 of 59




VALVE INFORMATON:

TAG NO: 11-HV-2071A SERVICE: Process Air SIZE: 8 "

AREA: AMM-3 FLANGE TYPE: FLG.RF(F)

PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Air leak test of actuator was found OK2. Overhauling3. Valve bench set was found4. Calibration5. Sent for Hydrotesting

DATE

05-05-2016

EXECUTED BY



AIR FAILURE CORRECT




POSITIONER CORRECT



Page 46 of 59




VALVE INFORMATON:



PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Cleaning, Oiling and Polishing2. Air Leak test of actuator was found OK3. Seat and plug were sent for machining4. All gaskets replaced5. Diapharm was found torned6. Diapharm replaced7. Calibrated8. Sent for Hydrotesting

DATE

05-05-2016

EXECUTED BY



AIR FAILURE CORRECT




POSITIONER CORRECT



Page 47 of 59




VALVE INFORMATON:



PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Air leak of acutator was tested and found OK2. Calibration was tested and found OK3. Cleaning, oiling and polishing was done4. Sent for Hydrotesting

DATE

05-05-2016

EXECUTED BY



AIR FAILURE CORRECT




POSITIONER CORRECT



Page 48 of 59




VALVE INFORMATON:


AREA: AMM-3 FLANGE TYPE: Lenticular

PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Actuator was found Leaked.2. Dismantled single diapharm of actuator (outter most)3. Body Overhauled4. Calibrated5. Sent for Hydrotesting

DATE

05-05-2016

EXECUTED BY



Close

SUPPLIED PRESSURE

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 49 of 59




VALVE INFORMATON:

TAG NO: 11-LV-3011B SERVICE: Process Air SIZE: 18 "


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Air leak test of actuator was found OK2. Overhauling of body3. Plug, seat and cage were sent for machining4. All three gaskets replaced5. Calibrated6. Sent for Hydrotesting

DATE

05-05-2016

EXECUTED BY

Mohammad Mubasher(Instrument Technician)


Open

SUPPLIED PRESSURE

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 50 of 59




VALVE INFORMATON:

TAG NO: 11-LV-3011A SERVICE: Process Air SIZE: 18 "


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Air leak test of actuator was found OK2. Overhauling of body3. Valve plug, cage and seat were sent for machining4. Cleaning, oiling and polishing were done to smoothen up the valve5. Calibrated6. Sent for Hydrotesting

DATE

05-05-2016

EXECUTED BY



Open

SUPPLIED PRESSURE

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 51 of 59




VALVE INFORMATON:

TAG NO: 19-PV-9001A SERVICE: Process Air SIZE: 4 "


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Cleaning, Oiling and Polishing2. Air Leak test of Actuator was found OK3. Diapharm was found Ok4. Overhauling of body and actuator5. O-rings replaced6. Seat, plug sent for machining7. All gaskets replaced8. Calibrated9. Sent For Hydrotesting

DATE

06-05-2016

EXECUTED BY



AIR FAILURE CORRECT




POSITIONER CORRECT



Page 52 of 59




VALVE INFORMATON:



PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Air leak test of actuator was found OK2. Overhauling of Body3. Overhauling of Actuator4. Seat and plug were sent for machining5. Body gaskets replaced6. Calibrated9. Sent For Hydrotesting

DATE

06-05-2016

EXECUTED BY



Close

SUPPLIED PRESSURE

40

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 53 of 59




VALVE INFORMATON:



PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Cleaning, Oiling and Polishing2. Air Leak test ok3. Overhauling of Body4. Overhauling of Actuator5. Diaphram was found OK6. O-Rings Replaced7. Plug and seat sent for machining8. Gland Packing Replaced9. Calibrated10. Sent For Hydrotesting

DATE

08-05-2016

EXECUTED BY



AIR FAILURE CORRECT




POSITIONER CORRECT



Page 54 of 59




VALVE INFORMATON:

TAG NO: 11-LV-2055 SERVICE: Process Air SIZE: 4-/-3-/-4


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Cleaning, Oiling and Polishing2. Air Leak test ok3. Overhauling of Body4. Overhauling of Actuator5. Seat Replaced6. Plug seal rings Replaced7. Plug and Stem sent for machining8. Gland Packing Replaced9. Calibrated10. Sent For Hydrotesting

DATE

08-05-2016

EXECUTED BY



Close

SUPPLIED PRESSURE

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 55 of 59




VALVE INFORMATON:



PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Cleaning, Oiling and Polishing2. Air Leak test ok3. Actuator Diapharm replaced4. Plug seal O-rings replaced9. Calibrated10. Sent For Hydrotesting

DATE

09-05-2016

EXECUTED BY



Close

SUPPLIED PRESSURE

AIR FAILURE CORRECT




POSITIONER CORRECT



Page 56 of 59




VALVE INFORMATON:



PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Cleaning, Oiling and Polishing2. Air Leak test ok3. Calibrated4. Sent For Hydrotesting

DATE

10-05-2016

EXECUTED BY



AIR FAILURE CORRECT




POSITIONER CORRECT



Page 57 of 59




VALVE INFORMATON:

TAG NO: 11-HV-1032B SERVICE: Process Air SIZE: 1 "


PHYSICAL CHECKS:






AIR FAILURE CORRECT




POSITIONER CORRECT



TEST RESULTS:




1. Cleaning, Oiling and Polishing2. Air Leak test ok3. Calibrated4. Sent For Hydrotesting

DATE

10-05-2016

EXECUTED BY



AIR FAILURE CORRECT




POSITIONER CORRECT



Page 58 of 59


7. PICTURES (Work In Progress):

Page 59 of 59

Review 004

Documents

Transcript of Review 004