DANAN Oil Field Development

N I O C
Iranian Central Oil Fields Co.
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DANAN Oil Field Development

Issue Purpose: For Approval

Result Code: A, B, R, N ( )
Next Status: FA, FI, FR, AFC, AB ( )
Resubmission Date: ( )
Approval or review hereunder shall not be construed to
relieve Vendor / Subcontractor of his responsibilities and
liability under the contract

CP Department ( )
Responsible Department ( )
Commented Date

DOCUMENT No

MP 980157

0 15-Sep-2016 M. J. V. KH. A. M. For Approval

REV. ISSUE DATE PREPARED CHECKED APPROVED PURPOSE OF ISSUE

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Index
1. Introduction ............................................................................................................................ 4
2. The range of products............................................................................................................. 4
3. Total flowchart of circulation of document ........................................................................... 5
4. Total flowchart of production process ................................................................................... 5
5. FAFCO’s Integrated Quality and Environmental Management System ................................ 7
6. Quality and Environmental Policy ......................................................................................... 9
7. Management System Overview.............................................................................................. 9
8. Quality Assurance Activities................................................................................................ 10
9. Quality Assurance in the Design Process ............................................................................. 11
10. Quality Assurance in Purchasing....................................................................................... 11
11. Quality Assurance in Production ...................................................................................... 13
12. After Sales Service ............................................................................................................ 13
13. Environmental Management ............................................................................................. 13
14. Quality Tests and Test Certificates ................................................................................... 13
15. Types of Test ..................................................................................................................... 14
16. Requirements for Standard Tests ....................................................................................... 14
17. Procedures ......................................................................................................................... 14
18. Test Certificates According to EN 10204 .......................................................................... 14
19. The most Relative Standards in manufacturing process ................................................... 15
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1. Introduction
The purpose of Manufacturing Procedure is
- Overview the production
- QC plan of shop processs
- QA of manufacturing
- What makes the difference between FAFCO and most competitors?
Manufacturing Procedure is a multi-faceted and multi-stage process. FAFCO therefore focuses
its QM activities on several related areas, which are described in detail below:
- The range of products
- Total flowchart of circulation of documents
- Total flowchart of production process
- FAFCO’s integrated Quality and Environmental Management System
- Requirements for the qualification of suppliers
- Requirements for components that are not manufactured in-house
- Requirements for the qualification of service partners
- Standard quality tests, procedures and certificates
- Quality tests performed on customer’s request
- Explanation of FAFCO’s Environmental Management activities

2. The range of products

Size
Product Range Set Point Range Standards Material Range
Range
Spring Loaded Safety Relief Valve 1 bar Up to 210 Bar
Normal
Pilot Operated Safety Relief Valve )1"-2"( 1 bar Up to 210 Bar
Up to
-0.5 mbar Up to
Vacuum Relief Valve )12"- -7 mbar ASME SEC VIII,
14"(, API 520,526,527 All Safety Valves
Low Pressure Pilot Operated Valve Custom 1 psi Up to 15 Psi
API 2000 materials plus materials
up to 1 psi/-0.5 mbar Up to in accordance with ISO
Pressure/Vacuum Relief Valve (18"-24") 15 Psi/
-7 mbar
15156/NACE MR 0175
And NACE MR 0103
Thermal Relief Valve (NPT Con. & 1/4" Up
1 bar Up to 210 Bar
Flange Con.) to 2"

1" Up to
ASME SEC I Safety Relief Valve 3.5 Bar Up to 255 Bar ASME SEC I
8"
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3. Total flowchart of circulation of document

4. Total flowchart of production process

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Material

To air (emission)

Waste / Recycle
Mold Core Melting (Mineral residue dust)
making making Process
(Return material)
Molding sand

Core
insertion
To air (emission) (Return material)
Abatement

Mold
register Casting
Process

Waste
(Binder residue)
Pouring
Recycle
(Cutting, grinding waste)

Mold Finishing Machinin

release g

Shipment Inspection Painting Assembly

process
Figure 1 Safety Relief Valves (Casting Body)
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Material

Burr removal Cutting

Recycling Process
(Forging junk)

Recycling (cutting,
grinding waste)

Machining Surface
Process Treatment

Assembly Degrease /
Cleaning
process

Inspection Shipment

Figure 2 Safety Relief Valves (Forged Body and Trim)

5. FAFCO’s Integrated Quality and Environmental Management

System
FAFCO is supplying safety valves to customers in Iran and makes sure that the products can be
used in most areas of Iran without requiring any change.

FAFCO has summarized the requirements of international codes and standards and has
transferred these into
- Internal processes
- Requirements for suppliers
- Requirements for purchased materials

The result is a Quality and Environmental Management System which integrates the
requirements of global quality and environmental standards.
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This includes the certification according to various regional and international regulations such
as:
- ISO TS 29001:2010
- CBS Type Approval(According to mandatory of ASME SEC VIII, API 520/526, API 2000,
ASME SEC I)
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6. Quality and Environmental Policy

With our safety valves we protect our clients’ products and facilities and thereby prevent harm
to people and the environment.

It is a matter of principle to FAFCO to provide each of our customers with products and services
of the required quality which comply with the customers’ specifications, the current norms and
the rules and regulations.

The required quality is achieved as a result of standardized and controlled processes, processes
that are shaped and carried out by our staff.

The achieved level of quality is therefore the collective result of the work done by each of our
employees and only meets the requirements when every employee carries out the tasks in his/her
field of activity self dependently and with quality awareness.

Only by ensuring the quality of our products and processes we can guarantee our objective to
provide protection and our financial success.

To achieve the required quality, we work with the regulations and methods specified in our
quality management system in accordance with (EN) ISO / TS 29001: 2010 . This is
perpetually being maintained and further developed in order to increase the effectiveness of the
regulations and methods.

Environmental issues form a vital part of our planning and implementation activities across the
processes of design, material management and production of FAFCO products.

A reasonable consideration of the environmental impact determines the type and scope of these
activities.

7. Management System Overview

FAFCO Quality Management comprises both the levels of strategic planning and operative
quality assurance.

On the strategic planning level, a large number of existing rules and regulations in the form of
FAFCO work standards and working instructions for the operative quality assurance are in
place in order to ensure compliance with rules and regulations within the controlled processes.

The operative quality assurance is the scheme which governs day to day operations. Quality
coordinators located in the individual operative departments ensure the implementation of
quality improving measures in all areas of activity of the order process.
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Q/E Management System

Strategic Planning level Operative Quality Assurance

Regulatory Affairs Quality Coordinator

Monitoring of
international codes and Design + Development
standards Purchasing
Adaption of procedures Machining
to changes in codes and Assembly
standards Sales
Performance + Customer claims
maintenance of third party
certification
Inspection supervisor
Incoming Goods
Machining
Assembly
Shipment
Operation Reliability

Monitoring of
internal business Welding supervisor
processes (Welders)
Introduction of guidelines
for operational quality FAFCO’s welding shop
assurance Procured welding
Corporate standards for
purchasing and production Customer Claims
Management

• Processing of customer
claims
• Performance/Endurance of
corrective and preventive
actions

8. Quality Assurance Activities

The high quality level of FAFCO safety valves is the result of coordinated processes, starting
with product development, through the assurance of high quality purchased materials and high-
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grade qualified production, combined with coordinated quality assurance measures within each
stage of production right up to the field application.

Service Production Purchasing Design

9. Quality Assurance in the Design Process

Quality assurance elements in all stages of product design are of key importance because this is
where the greatest potential for cost reduction and quality improvement lies.

For this reason FAFCO has implemented elements like design reviews, process and design
FMEAs
(Failure mode and effect analysis) into the design process.

Furthermore, product validation testing is conducted on our performance test lab, assuring the
high quality of FAFCO safety valves already at the design stage.

In addition to the product validation testing required for the approval of a safety valve, regular
product audits are performed by FAFCO.
A product audit is performed on production valves and consists of the following checks and
verifications:
- Capacity and function: performance tests on flow test lab
- Set pressure: according to specification
- Tightness: according to specification, API 527, API 2000, ASME SEC I, ISO 4126
- Documentation: order confirmation, material certificates
- Material certificates: compliance of materials with ASME VIII and ASME II, PED 97/23/EC
- Marking: consistency between packing, tag and name plate
- Valve external: no external damages
- Dimensions: dimensional check of critical dimensions
- Consistency of information: comparison of information in catalog and FAFCO order handling
system.

10. Quality Assurance in Purchasing

The requirements for purchased parts are laid down in FAFCO’s corporate purchasing
procedure.
These document summarize the requirements of worldwide codes and standards (e.g. PED and
ASME Code) and serve as contractual requirements for all tests and qualifications.
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At the beginning of the purchasing process, the first step is the selection and qualification of
suppliers.
FAFCO’s requires a stringent qualification of new suppliers and continuous monitoring
of established suppliers. LFAFCO uses a comprehensive qualification system established in a
supplier development process with the following topics:

- Check required certifications

- Requirements for supplier’s quality system certifications, qualifications of staff and
processes
- External audits of the supplier’s quality management system and manufacturing
equipment
- First sample examination process (6 sample lot per each new part)
- Continuous supplier assessment by incoming inspection
- Quality Assurance Agreements with suppliers which are then integrated into the FAFCO
Quality Management System.
The following example shows requirements and procedure for the qualification of a new
supplier for casting materials:

Requirement Process Step

ISO 29001, PED 97/23/EC, LR,
GL, DNV, requirements are laid
down in Purchasing Procedure
Verification of requirements
above mentioned requirements
regarding: certifications,
equipment, with
Conformity personnel.
drawings
First sample inspection
requirements are laid down
FAFCO Purchasing Procedure
ISO 29001, PED
97/23/EC, ASME VIII
App. 10.
First sample inspection
requirements are laid down in
FAFCO Purchasing Procedure
Preselection of supplier 1
Supplier audit by QM and Purchasing 2
Implementation of FAFCO specified 3
casting pattern by supplier
Supply of first sample lot to FAFCO: 4
6 sample lot for each new part with first
sample inspection performed by supplier
First sample inspection process at FAFCO 5
- review of material certificate, spectral
analysis
- 100% incoming inspection of samples,
dimensional check, radiographic test
- machining of all samples with tools used
during serial production: shows possible
internal defects
- documentation of results in a
specific first sample test report form
- Result: approved, approved with
conditions, not approved…
Approval of new part for supplier 6
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Should quality deviations occur after the part has been approved, FAFCO uses a claim
management process which secures that corrective and preventive measures are taken by the
supplier. FAFCO’s established supplier management system guarantees the FAFCO specific
development of suppliers in order to attain a high quality level.

11. Quality Assurance in Production

Machining, welding, pickling and assembly are integrated in the production process at the
factory in Arak (Iran). This deep vertical integration allows hands-on access to the processes and
quick response times.

This process control is ensured by:

- Quality inspectors and workers in the machining department who are directly responsible
for inspections according to specified inspection plans.
- Inspection supervisors trained according to
- EN 473 – Non-Destructive Testing – Qualification and Certification of NDT Personnel and
- SNT-TC-1A - Non-Destructive testing who check the non-destructive inspections for cast and
welded parts.
- Welding supervisors who qualify the welding procedures together with external
inspectors.
- Quality coordinators who ensure the quality of the individual operational processes and
who are especially trained as certified individuals according to ASME VIII UG 117.

12. After Sales Service

After the valves are delivered to the customer FAFCO Test Certificate ensure the functionality
of the products during the product life cycle.

Phone: +98 86 34134208

Fax : +98 86 34134207
E-mail: Sales@FAFCO.ir

13. Environmental Management

The System ensures that FAFCO uses resources carefully and relevant processes are in place to
reduce the environmental impact.

Environmental programs and objectives form the basis of the use of environmentally friendly
technologies and serve as guidelines.

14. Quality Tests and Test Certificates

FAFCO offers all relevant types of tests, including tests performed on customers’ request and
third party inspections. Testing is based on internationally applicable standards and on a large
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number of national codes and their requirements. There is extensive documentation of test
procedures available. FAFCO issues a variety of certificates.

15. Types of Test

FAFCO performs the following types of tests or will arrange for them to be performed by a third
party:
•FAFCO standard tests – required by international codes and standards (see section 11.5.2)
 Body strength
 Set pressure
 Tightness Seat/Body, etc.
• Material Tests – performed by supplier or external laboratories
 Strength tests
 Chemical analysis,
 NDE tests, etc.
• Additional Tests – performed by FAFCO on customer’s request
• Third Party Inspections

16. Requirements for Standard Tests

The requirements for the FAFCO standard tests which are certified by the FAFCO Certificate
for Global Application.

Option Code Directive Test Description

TE1 ASME Code Sec FAFCO Certificate for
VIII Global
API 526 Application
DIN EN ISO 4126
DIN EN 12266 1/2
PED
97/23/EG
AD 2000-
17. Procedures
A2
FAFCO’s test procedures are documented in FAFCO work standards. The standards contain
detailed information about:
* Test reference * Scope and definition * Applicability
* Acceptance criteria * Test procedure * Test equipment
* Standard references * Documentation * Personal qualification
18. Test Certificates According to EN 10204
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According to the EN 10204 standard FAFCO offers three different types of certificates as
follows:

Test report
Document in which the manufacturer declares that the products supplied are in compliance with
the requirements of the order and in which he supplies test results based on non-specific
inspection.

Inspection Certificate 1.

Document issued by the manufacturer in which he declares that the product supplied are
in compliance with the requirements of the order and in which he supplies test results.

The test unit and the tests to be carried out are defined by the product specification, the official
regulation and corresponding rules and/or the order.

The document is validated by the manufacturer’s authorized inspection representative,

independent of the manufacturing department.

Inspection Certificate 2.

Document prepared by both the manufacturer’s authorized inspection representative,

independent of the manufacturing department and either the purchaser’s authorized inspection
representative or the inspector designated by the official regulations and in which they declare
that the products supplied are in compliance with the requirements of the order and in which test
results are supplied.

The majority of the certificates issued by FAFCO are Inspection Certificates 1.

19. The most Relative Standards in manufacturing

process
• ASME SEC VIII
• ASME SEC I
• API 520/API 526/API 527
• API 2000
• ASTM
• MSS SP15
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• ASME B16.34
• ASME B16.5
• IPS
• IGS-IN-302
• AISI
• ISO 4126-1 to 9