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 0 2 OF 6 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 PAGE 8-Apr-03 AVI-P-FC-001A 0 3 OF 6 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 8-Apr-03 AVI-P-FC-001A 0 4 OF 6 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 0 6 OF 6 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