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PT. ALFA VALVES INDONESIA


JL. 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 : alfavalve@cbn.net.id
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 may
be copied in a whole or in apart thereof or transferred to a third party or used in any other way detrimental to the interest of
PT. ALFA VALVES INDONESIA.
Notice
ALFA VALVES
DOC NO.
REV.
AVI-P-FC-001A
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DATE OF ISSUED
PAGE
8-Apr-03
PRODUCTION PROCESS FLOW CHART OF TRUNNION BALL VALVE
#
-
materials againts packing list or supplier
supplier D/D / invoice to Alfa. PO.
Discrepancies shall be identifed
DOCUMENT REMARK
Check for correct content and quantity
Store 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 identifed
for remedial action
Material stock status raised
for Direct Material record
Materials consumable log book
raised 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 thickness
Dimensional Inspection
meeting receive reports & decide
material status
NO
* Face to Face/End to End Dimensions
NCMR ( Non Conforming Material
MRB ( Material Review Board)
* Flange Dimensions
NCMR NC Tag
OK ? NON-CONFORMANCE
YES
-
#
#
-
Production Assembly Operator
Production 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 Operator
Inspect for Quantity and suitability of
Sales Order and / or customer delivery
order
Production Assembly Operator
NO
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 NCMR
OK ? OK ?
-
#
NCP : Non-Conformance Procedure
Production Assembly Operator
YES
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
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8-Apr-03 AVI-P-FC-001A
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PRODUCTION PROCESS FLOW CHART OF TRUNNION BALL VALVE
#
#
MRB
Production AssemblyOperator
PROCESS DOCUMENT
YES
YES
REMARK
NO NO
NCMR
A
OK ?
TRIAL &
ERROR
OK ? NCP
#
#
#
MRB
P d ti A bl O t
Production Assembly Operator YES
YES
YES
NO NO
INSTALL
BODY SEAT
RETAINER (1)
ASSY INTO
BODY
OK ?
TRIAL &
ERROR
OK ? NCP
ASSY IN-PROCESS
NCMR
#
#
#
Production Assembly Operator
MRB
NO NO
YES
YES
YES
Production Assembly Operator
INSTALL
BODY SEAT
O-RING
OK ?
TRIAL &
ERROR
OK ? NCP
INSTALL
NCMR
ASSY IN-PROCESS
ASSY IN-PROCESS
#
#
MRB
YES
Production Assembly Operator
NO NO
YES
INSTALL
BALL INTO
BODY
OK ?
TRIAL &
ERROR
OK ? NCP
INSTALL O-
RING
NCMR
ASSY IN PROCESS
ASSY IN-PROCESS
#
#
NO NO
YES
YES
MRB
Production AssemblyOperator
RING,
BEARING
INTO LOWER
STEM
OK ?
TRIAL &
ERROR
OK ? NCP
NCMR
#
#
#
NO
YES
YES Production Assembly Operator
Production Assembly Operator
MRB NO
INSTALL
LOWER
STEM ASSY
INTO BALL
OK ?
TRIAL &
ERROR
OK ?
NCP
NCMR
ASSY IN-PROCESS
YES
INSTALL
THRUST
BEARING &
THRUST
WASHER
INTO LOWER
STEM
B
ASSY IN-PROCESS
AVI-P-FC-001A
PRODUCTION PROCESS FLOW CHART OF TRUNNION BALL VALVE
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ALFA VALVES
DOC NO.
REV.
DATE OF ISSUED
PAGE
#
#
NO NO
PROCESS DOCUMENT
YES
YES
REMARK
Production AssemblyOperator
MRB
NCMR
B
OK ?
TRIAL &
ERROR
OK ? NCP
#
#
YES
YES
Production Assembly Operator
Production Assembly Operator
BOLTING
LOWER
COVER INTO
BODY WITH
STUD BOLTS
& NUTS
ASSY IN-PROCESS
INSTALL
BEARING,
ASSY IN-PROCESS
#
NO NO
YES
YES
MRB
,
THRUST
WASHER &
O-RING INTO
UPPER STEM
OK ?
TRIAL &
ERROR
OK ? NCP
NCMR
#
#
#
YES
Production AssemblyOperator
NO NO
YES
Production Assembly Operator
MRB
INSTALL
UPPER STEM
ASSY INTO
BALL
OK ?
TRIAL &
ERROR
OK ? NCP
NCMR
ASSY IN-PROCESS
#
#
Production Assembly Operator
YES
YES
NO NO
MRB
BOLTING
GLAND ASSY
INTO BODY
WITH HEX
HEAD BOLTS
OK ?
TRIAL &
ERROR
OK ? NCP
NCMR
ASSY IN-PROCESS
#
#
MRB NO
YES
NO
YES
Production Assembly Operator
INSTALL
SEAT O-RING
INTO CAP
OK ?
TRIAL &
ERROR
OK ?
NCP
NCMR
ASSY IN-PROCESS
# YES Production Assembly Operator
INSTALL
GASKET & O-
RING
BETWEEN
BODY AND
CAP
C
ASSY IN-PROCESS
AVI-P-FC-001A
ALFA VALVES
DOC NO.
REV.
DATE OF ISSUED
PAGE 0
8-Apr-03 AVI-P-FC-001A
5 OF 6
PRODUCTION PROCESS FLOW CHART OF TRUNNION BALL VALVE
#
PROCESS DOCUMENT REMARK
Production Assembly Operator
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
YES
YES
MRB
Production Assembly Operator
OK ?
TRIAL &
ERROR
OK ? NCP
INSTALL
DRAIN PLUG
INTO BODY
NCMR
ASSY IN-PROCESS
#
#
MRB
YES
NO NO
YES
Production Assembly Operator
OK ?
TRIAL &
ERROR
OK ? NCP
INSTALL
STEM KEY
INTO STEM
NCMR
ASSY IN-PROCESS
#
#
-
MRB
NO
Production Assembly Operator
For Lever Operator Ball Valves to
NO
Install Lever into Ball Valve :
YES
OK ?
TRIAL &
ERROR
OK ? NCP
NCMR
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 REPORT VALVE ASSY
INSPECTION
OPERATOR
ASSY INTO
VALVE
MOUNTING
PAD WITH
HEX HEAD
BOLTS
-
#
YES
NO
J oint torques Inspection
NO
MRB
YES
OK ?
TRIAL &
ERROR
OK ? NCP
D
INSPECTION
NCMR
AVI-P-FC-001A
ALFA VALVES
DOC NO.
REV.
DATE OF ISSUED
PAGE
8-Apr-03 AVI-P-FC-001A
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PRODUCTION PROCESS FLOW CHART OF TRUNNION BALL VALVE
#
-
-
REMARK PROCESS DOCUMENT
Production Testing Operator
Shell Test
Low-Pressure Closure Test
High-Pressure Closure Test
D
VALVE
PRESSURE
TESTING DAILY
PERFORMANCE REPORT
-
-
#
#
API 598 or API 6D
(Upon Customer's Requirements)
YES
NO
MRB
Production Painting Operator
High-Pressure Closure Test
COATING
COATING DAILY
PERFORMANCE REPORT
TESTING
NON-CONFORMANCE OK ?
NCMR NC Tag
#
-
#
-
The Plates are mounted in the most
practicable position
Production Packing Operator
QC Inspector
Production will advise QC that valves
INSTALL ID
PLATE
COATING
FINAL
PERFORMANCE REPORT
REQUEST for QC QC FINAL INSPECTION
#
#
are ready for final Inspection by
Completing a"Request for QC
Inspection Form"
NO
YES
Production Packing Operator
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
Production Packing Operator
PACKAGING
& DESPATCH
DOCUMENTA
TION
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