TABLE OF CONTENTS -...

Valve Group – Farris Engineering

Standard Operating Procedures – Procedure

Title: Purchasing Standard and Material Acceptance Criteria

Rev. Level: 5

Doc.#: SOP-GP-15 Rev. Date: Jan 30, 2015 This document is electronically controlled and stored on a network drive. Printed versions are uncontrolled and for reference purposes only unless otherwise indicated.

TABLE OF CONTENTS

1. Scope 2. Reference Specifications 3. Ordering Information 4. Source Inspection at Foundry 5. Shipping Preparation for Castings 6. Incoming Inspection at Farris – All Material 7. Incoming Inspection at Farris of Sample Castings 8. Incoming Inspection at Farris of Production Castings 9. General Requirements for Castings 10. Hydrostatic Testing

A. Hydrostatic Test Specification for Machined Bodies/Bonnets B. Hydrostatic Test Specification for Nozzles

11. Lapping 12. Scrap and Rework 13. Salvage Procedure on Rejects

Appendix I: Inspection Criteria for Procured Finish Machined Castings / Parts I-A. Sleeve Guide I-B. Blow Down Ring I-C. Disc Holder I-D. Stem Retainer I-E. Nozzle I-F. Bonnet I-G. Body

Appendix II: Inspection Criteria for Procured Finish Machined Castings / Parts II-A. Sleeve Guide II-B. Blow Down Ring II-C. Disc Holder II-D. Stem Retainer II-E. Nozzle II-F. Bonnet II-G. Body

1. SCOPE

All parts listed must be purchased in accordance with this specification.

2. REFERENCE SPECIFICATIONS

The following Farris Engineering standards are mandatory and must be adhered to when this SOP is called

out. In case of conflict between this SOP and any other, this SOP shall take precedence.

MS-14 Surface Finish FEB-08-02 Receiving Inspection




Rev. Level: 5


MSS SP 55 Manufacturers Standardization Society of the Valves and Fittings

Industry: Standard Practice SP-55 (Quality Standard for Valves, Flanges and Fittings and Other Piping Components – Visual Method)

FEB-10-01 Inspection and Testing FEB-10-07 Sample Inspection Process FEB-13-02 DPR/Non conformance classification SOP-GP-01 Operation and Maintenance of Lapping Machines SOP-GP-09 Measurement of Lapping Plate Flatness using Optical Flats SOP-GP-13 Hydrostatic Testing Requirements for Finish Machined 2600 / 3800

Bodies and 2600 Bonnets ANSI B16.5-1996 Pipe Flanges and Flanged Fittings

3. ORDERING NUMBER

The purchase order shall not be considered complete unless all of the following information is provided and

referenced by item number.

3.1. A description of the casting by pattern number, drawing number and revision. 3.2. A description of the finished machined part by Part Number, Drawing Number and Drawing Revision

Letter. 3.3. Material specification and grade number. All Body, Bonnet and Yoke castings must be produced and

certified to an ASME (American Society of Mechanical Engineers) material specification. These material specifications must carry the prefix “SA”.

3.4. Any supplementary requirements, if any. State none if not required. 3.5. Quantity of castings. 3.6. Compliance with this Farris Engineering Brantford SOP is mandatory. This includes third party source

inspection at the foundry and shipping preparation. 3.7. State if sample castings are required and quantity. 3.8. State “Castings shall not be peened, plugged of impregnated to stop leaks”. 3.9. Source inspection required for this Purchase Order. Describe the approved agency. 3.10. All original copies of material test reports shall be included with the shipment enclosed in a

waterproof envelope.

4. SOURCE INSPECTION AT FOUNDRY

(Inspection Agency to be specified by Farris Engineering). Each lot of castings or machined parts is to be

sample inspected in accordance with FEB-08-02 (Table A)

4.1. Verify heat numbers are clearly stamped or cast on castings at specified location. 4.2. Verify part number and material identification is clearly marked on castings at specified location. 4.3. Castings shall be subject to visual inspection of all surfaces per MSS-SP-55. 4.4. Verify shipping preparation per paragraphs 5.1 - 5.5 of this SOP for finished machine castings only.




Rev. Level: 5


5. SHIPPING PREPARATION FOR CASTINGS

Paragraphs 5.1,5.2 and 5.3 apply only to finished machined castings.

5.1. All carbon steel machined surfaces shall be coated with a rust inhibitor such as MOBILARMA 247 manufactured by Mobil Oil, or other similar coatings, which have been approved by Farris Engineering.

5.2. All threaded areas to be protected with plastic type plugs or caps. 5.3. All flanged faces and other machined surfaces shall be covered with flange protectors to their

maximum diameter and securely attached. Flange protectors shall be no less than ¼ inch thick masonite or standard polyethylene protectors.

5.4. The packaging and stacking of castings must be arranged so as to prevent any contact or shifting of contents, which may damage castings.

5.5. If closed wooden crates suitable for export shipment by ocean freight are used, they shall be treated and certified to be pest free. Metal crates are preferred. Crate interior shall be lined with waterproof paper. Crate design shall allow handling by forklift with maximum exterior crate dimensions not to exceed 48” high x 72” long x 84” wide. Maximum shipping weight shall not exceed 3000 pounds per crate.

6. INCOMING INSPECTION AT FARRIS – ALL MATERIAL

6.1. Material certification must accompany shipment, when specified and be a photocopy copy. The original is to be mailed separately.

6.2. Verify heat numbers of castings supplied against material certification. 6.3. Check material certification for content and compliance to ASTM/ASME. 6.4. Visual Inspection for shipping damage.

7. INCOMING INSPECTION AT FARRIS OF “SAMPLE” PARTS

(Condition: “As Cast or Machined”)

7.1. Work Instruction FEB-10-07 “Sample Inspection Process” shall be followed in planning and inspecting sample castings. A minimum of two pieces shall be inspected to verify wall thickness. The QC Department shall complete the appropriate Wall Map located in the Work Instruction.

7.2. A hydrostatic test shall be performed on a minimum of two castings. 7.3. Inspection per MSS SP 55 shall be performed on “as cast” sample castings. 7.4. Dimensional inspection per FEB-08-02 (Table A) shall be performed on all “machined” sample

castings.

8. INCOMING INSPECTION AT FARRIS OF PRODUCTION CASTINGS

8.1. A visual profile check shall be performed to check for: a. Out of Roundness b. Warped Flanges c. Insufficient finish allowance d. Excessive Core Shift

8.2. The casting shall be subject to inspection of all surfaces, particularly surfaces exposed by machining or drilling, without revealing any injurious defects. Refer to Appendix I & II. They both outline criteria applicable to all production castings, irrespective of procurement source.




Rev. Level: 5


8.3. Dimensional inspection of parts per FEB-08-02 (Table A). 8.4. As cast surfaces shall be subject to visual inspection per MSS-SP-55.

9. GENERAL REQUIREMENTS FOR CASTINGS

9.1. All castings furnished to Farris affiliated companies regardless of material will be rejected if found porous on:

a. a. Finished Machined Surfaces b. b. Back Pressure Test c. c. Hydrostatic Test

9.2. All castings will be rejected when concentricity of internal core and external periphery shifts more than 1/8 inch full indicator reading. Tighter tolerances may be indicated on the specific casting drawing.

9.3. Each casting will be subject to inspection of all surfaces, particularly such as are exposed by machining or drilling, without revealing any injurious defects.

9.4. Where defects, not impairing the strength of the casting have been repaired by welding, the repaired casting shall be stress relieved. Weld repairs shall be limited to bodies, bonnets and caps of safety and relief valves. Welding of any other parts shall have prior approval of QC Manager, in which case the repaired casting shall be handled as a rough casting in the area of distortion. Any part repaired by welding shall be 100% inspected for all machined dimensions after welding and stress relieving, whether re-machined or not.

9.5. Cast materials shall not be impregnated, peened or plugged to stop leaks. 9.6. Full and semi-nozzle castings and bodies and bonnets in all materials shall be hydrostatically tested

after machining.

10. HYDROSTATIC TESTING

When specified and if within capabilities of the vendor/ supplier, nozzles, bodies and bonnets shall be

pressure tested after machining at a pressure 1-1/2 times the design pressure of the part. No external

visible leakage is permissible.

Hydrostatic Test Specification for Machined Bodies / Bonnets:

As per Farris Engineering Brantford Standard Operating Procedure SOP-GP-13

Hydrostatic Test Specification for Nozzles:

As per Farris Engineering Brantford Standard Operating Procedure FEB-10-01

11. LAPPING

When specified and if within capabilities of the vendor / supplier, all nozzle seat and disc seat areas shall be imparted a surface finish of at least a Ra of 4-6 micro-inches (AARH) and a flat surface (as close to ‘zero’ light band when surface is viewed through an optical flat under a monochromatic light source). Lapping of these parts using a lapping plate, abrasive slurry and vehicle may be carried out with reference to the Farris Engineering Brantford Standard Operating Procedure SOP-GP-01. Measurement of flatness by optical flats (optional) is outlined in the Farris Engineering Brantford Standard Operating Procedure SOP-GP-09.

12. SCRAP AND REWORK

Process in accordance with Work Instruction FEB-13-02 “DPR/Non-conformance classification”




Rev. Level: 5


13. SALVAGE PROCEDURE ON REJECTS

Machine Shop Lead Hand will decide on all cases of minute porosity and defects rejected by Machinists on

DPRs. Parts rejected may be reworked, if economical, to the minimum of the print tolerance to see if the

part characteristics can be brought within the acceptable limits.

____________________________________________________________________________________

APPENDIX I

INSPECTION CRITERIA FOR FINISH MACHINED PARTS: Orifice D Through P 2600 Series ____________________________________________________________________________________ I-A. SLEEVE GUIDE

Finish machined Sleeve Guides shall be inspected on areas marked and instructions given below: Area A: Finished Bore & Bore ends and both sides of Flange and Flange OD within 3/8“ of the OD. Area B: Other machined surfaces. Area C: All other surfaces. As cast surfaces shall be subject to visual inspection per MSS-SP-55.




Rev. Level: 5


Table A

Surface

Max. Allowable Defect Size Number of Defects

Concentration* Maximum

A+ 0.000” 0 0

B 0.020” 3 3

C 0.030” 3 5

+ inside sleeve guide barrel upto a distance of d/4 where d=bore diameter.

* Concentration = max. number allowed within ½” diameter circle. They should be spaced apart from each

other by a minimum distance equal to the largest defect diameter.

Reject all pieces with one or more defect at the intersections (corners / crevices) of the guiding /

machined / cast surface.

Reject pieces with defect in and around the same location on both sides of the part walls.

I-B. BLOW DOWN RING

Finish machined Blow Down Rings shall be inspected on the areas marked: Area A: Front Face and Bore Area B: Bore Threads and Recess Area C: All other surfaces As cast surfaces shall be subject to visual inspection per MSS-SP-55.




Rev. Level: 5


Table B

Surface

Max. Allowable

Defect Size

Number of Defects


A 0.001” 2 3

B 0.005” 3 3

C 0.020” 3 5






Rev. Level: 5


I-C. DISC HOLDER

Finish machined Disc Holders shall be inspected on the areas marked. Area A: Spherical radius (primary guiding surface) & threads Area B: Secondary guiding surface Area C: All other surfaces As cast surfaces shall be subject to visual inspection per MSS-SP-55.

Table C

Surface

Max. Allowable

Defect Size

Number of Defects


A 0.001” 2 3

B 0.005” 3 3

C 0.020” 3 5






Rev. Level: 5


Reject all pieces with one or more defects at the intersections (corners / crevices) of the guiding /






Rev. Level: 5


I-D. STEM RETAINER

Finish machined Stem Retainers shall be inspected on the areas marked. Area A: Primary guiding surface & threads Area B: Secondary guiding surface Area C: All other surfaces as indicated As cast surfaces shall be subject to visual inspection per MSS-SP-55.

Table D

Surface

Max. Allowable

Defect Size

Number of Defects


A 0.000” 0 0

B 0.005” 3 3

C 0.020” 3 5




Rev. Level: 5







I-E. NOZZLE

Finish machined Nozzles shall be inspected on the areas marked. Area A: Seat and adjacent area to the top of the blowdown ring threads Area B: Nozzle bore surface, flange face, threads and others as shown Area C: All other surfaces as indicated As cast surfaces shall be subject to visual inspection per MSS-SP-55.

Table E




Rev. Level: 5


Surface

Max. Allowable

Defect Size

Number of Defects


A 0.000” 0 0

B 0.030” 3 3

C 0.050” 3 5

Surface D

Allowable Maximum radial projection of imperfections which are no deeper than the bottom of the serrations =

0.120”

Adjacent imperfections shall be separated by a distance of at least four times the actual maximum radial

projection. A radial projection shall be measured by the difference between an outer radius and an inner

radius encompassing the imperfection where the radii are struck from the centerline of the bore.

Imperfections less than half the length of the serrations shall not be considered cause for rejection.

Protrusions above the serrations are not permitted.

Maximum depth and radial projection of imperfections which are deeper than the bottom of the serrations =

0.060”









Rev. Level: 5


I-F. BONNET

Finish machined Bonnets shall be inspected on the areas marked.

Area A: Counterbore, threads and bolt holes as indicated. Area B: Flange edge, pipe threads and other areas as indicated. Area C: All other surfaces as indicated As cast surfaces shall be subject to visual inspection per MSS-SP-55.

Table F

Surface Max. Allowable Number of Defects




Rev. Level: 5


Defect Size Concentration* Maximum

A 0.005” 2 5

B 0.030” 3 5

C 0.060” 3 5





Reject pieces with defect within distance = bolt hole radius + ¼” of the bolt holes.


I-G. BODY

Finish machined Bodies shall be inspected on the areas marked: Area A: Gasket face, counterbore, stud holes, pipe plug threads, BDR Lock Screw threads / gasket surface Area B: Inlet Bore and Threads, outer flange areas Area C: Outer cast surfaces

As cast surfaces shall be subject to visual inspection per MSS-SP-55.




Rev. Level: 5


Table G

Surface

Max. Allowable

Defect Size

Number of Defects


A 0.005” 0 1

B 0.030” 3 3

C 0.060” 3 5

Surface D

Allowable Maximum Radial Projection of Imperfections which are no deeper than the bottom of the serrations =

0.120”









Rev. Level: 5



0.060”





Reject pieces with defect within distance = ¼” from the edge of the bolt holes.


____________________________________________________________________________________

APPENDIX II

INSPECTION CRITERIA FOR FINISH MACHINED PARTS: Q, R & T 2600 Series

____________________________________________________________________________________

II-A. SLEEVE GUIDE

Area A: Finished Bore & Bore ends, both sides of Flange and Flange OD within 3/4“ of the OD. Area B: Remainder of flange surface and inner bore. Area C: Machined surfaces as indicated. Area D: Other surfaces as indicated as cast surfaces shall be subject to visual inspection per MSS-SP-55.




Rev. Level: 5


Table I

Surface Max. Allowable Defect

Size

Number of Defects

Concentration * Maximum

A Zero 0 0

B 0.010” 3 3

C 0.030” 3 5

D 0.060" 3 7




Rev. Level: 5


Concentration = max. number allowed within ½” diameter circle. They should be spaced apart from each


In case of sleeve guide bore, distance of d/4 from the barrel ends where d is the inside diameter.

In case of sleeve guide flange, distance of 3/4" from the edge of the flange.

II-B. BLOW DOWN RING

Area A: Top Face, guiding surface Area B: Bore Threads Area C: Machined surfaces like recess and other surfaces Area D: Other surfaces as indicated, as cast surfaces shall be subject to visual inspection per MSS-SP-55.

Table II

Surface

Max. Allowable

Defect Size

Number of Defects


A Zero 0 0




Rev. Level: 5


B 0.010” 3 4

C 0.030” 3 5

D 0.060" 3 7

*Concentration = max. number allowed within ½” diameter circle. They should be spaced apart from each





Rev. Level: 5


II-C. DISC HOLDER

Area A: Spherical radius (primary guiding and sealing surfaces). Area B: Secondary guiding and sealing surfaces. Area C: Other machined surfaces. Area D: All other surfaces, as cast surfaces shall be subject to visual inspection per MSS-SP-55.

Table III

Surface

Max. Allowable

Defect Size

Number of Defects


A Zero 0 0

B 0.010” 3 4

C 0.030” 3 5

D 0.040" 3 7






Rev. Level: 5


II-D. STEM RETAINER

Area A: Majority of primary guiding (sliding) surface. Area B: Threaded and some guiding surfaces. Area C: Other machined surfaces. Area D: Other surfaces, as cast surfaces shall be subject to visual inspection per MSS-SP-55.

Table IV

Surface

Max. Allowable

Defect Size

Number of Defects


A Zero 0 0

B 0.010” 3 4

C 0.030” 3 5

D 0.060" 3 7




Rev. Level: 5




In case of stem retainer outside surface, surface B is up to 1" from the back of the flange.

II-E. NOZZLE

Area A: Seat and sealing surfaces. Area B: Nozzle bore surface, flange face, threads and others as shown. Area C and D: All other surfaces as indicated, as cast surfaces shall be subject to visual inspection per MSS-

SP-55.

Table V

Surface

Max. Allowable

Defect Size

Number of Defects





Rev. Level: 5


A Zero 0 0

B 0.010” 3 4

C 0.030” 3 5

D 0.060" 3 7

Surface E

Allowable Maximum radial projection of imperfections which are no deeper than the bottom of the serrations =

0.120”







0.060”









Rev. Level: 5





Rev. Level: 5


II-F. BONNET

Area A: Bonnet sealing surfaces (Counterbore: 3/4" from the corner, Cap interface area: 1/2" from cap threads).

Area B: Threaded areas, back spot faced surfaces and remainder of cap/ bonnet interface. Area C: Other machined surfaces. Area D: Other surfaces, as cast surfaces shall be subject to visual inspection per MSS-SP-55.

Table VI




Rev. Level: 5


Surface

Max. Allowable

Defect Size

Number of Defects


A Zero 0 0

B 0.010” 3 4

C 0.030” 3 5

D 0.060" 3 7





Reject pieces with defect within distance = bolt hole radius + ¼” of the bolt holes.


II-G. BODY

Area A: Gasket and sealing surfaces, counterbore, BDR Lock Screw thread face, Nozzle flange/ body flange interface.

Area B: Threading areas. Area C and D: Other surfaces, as cast surfaces shall be subject to visual inspection per MSS-SP-55.




Rev. Level: 5


Table VII

Surface Max. Allowable

Defect Size

Number of Defects


A Zero 0 0

B 0.010” 3 4

C 0.030” 3 5

D 0.060" 3 7

Surface D

Allowable Maximum Radial Projection of Imperfections which are no deeper than the bottom of the serrations =

0.120”







0.060”




Rev. Level: 5




Reject all pieces with one or more defects at the intersections (corners/ crevices) of the guiding/ machined/

cast surface.

Reject pieces with defect within distance = ¼” from the edge of the bolt holes.


TABLE OF CONTENTS -...

Documents

Transcript of TABLE OF CONTENTS -...