28-08-2014, 03:15 PM
INDUSTRIAL VALVE PLANT IS SITUATED AT GOINDWAL SAHIB PUNJAB. IT IS PRODUCT OF BHEL (Bharat Heavy Electrical Ltd.) THERE HAS MANUFACTURING OF INDUSTRIAL VALVES UPTO 24 INCH FROM 2 INCH. AT BHEL OUR PROJECT IS HYDRO TEST ANALYSIS.
CHATER I
INTRODUCTION
1.1 Introduction of Company
1.2 Intradepartmental exposure:
1.3 Necessity of Valves
1.1 INTRODUCTION
BHEL – IVP, GOINDWAL SAHIB
BHELis the largest engineering and manufacturing enterprise in India in the energy-related/infrastructure sector, today.BHEL was established more than 40 years ago, ushering in the indigenous Heavy Electrical Equipment industry in India - a dream that has been more than realized with a well-recognized track record of performance. The company has been earning profits continuously since 1971-72 and paying dividends since 1976-77.
BHELmanufactures over 180 products under 30 major product groups and caters to core sectors of the Indian Economy viz., Power Generation & Transmission, Industry, Transportation, Renewable Energy, etc. The wide network ofBHEL's 14 manufacturing divisions, four Power Sector regional centers, over 100 project sites, eight service centers, 18 regional offices and one subsidiary enables the Company to promptly serve its customers and provide them with suitable products, systems and services -- efficiently and at competitive prices. The high level of quality & reliability of its products is due to the emphasis on design, engineering and manufacturing to international standards by acquiring and adapting some of the best technologies from leading companies in the world, together with technologies developed in its own R&D centers.
BHELhas acquired certifications to Quality Management Systems (ISO 9001), Environmental Management Systems (ISO 14001) and Occupational Health & Safety Management Systems (OHSAS 18001) and is also well on its journey towards Total Quality Management.
Goindwal Sahib is a historic and revered town founded by the third Sikh Guru Amar Das Ji in 1546 A.D., situated on Sher Shah Suri marg running from Kolkata to Peshawar. In the year 1979, the central government decided to set up first nucleus industrial tour at Goindwal Sahib.
In line policy declared by govt. of India in July 1980,for the development of nucleus industrial tours, BHEL management took decision to establish industrial valve plant at Goindwal Sahib with the initial capital investment of Rs. 3 crore. Industrial valve plant is a part of BHEL Trichy complex. It is one of the major complexes of BHEL and comprising of high pressure boiling plant(HPBP), seamless steel tube plant(SSTP), piping centre of Chennai, Boiler auxiliaries plant (BAP) at Ranipat and industrial valve plant(IVP) at Goindwal. The complex is headed by executive director who is the member of the management committee and reports the company’s CMD.
The present manufacturing range of valves at IVP, Goindwal covers 2’’ to 24’’ valves with different material specifications from carbon steel to stainless steel with a variety of special features like motorized/geared operation, limit switches arrangement, indicator arrangement, lock/chain wheel arrangement and other required by customer.
1.2 INTRADEPARTMENTAL EXPOSURE:
A. PRODUCTION DEPARTMENT
Production is the functional area responsible for turning inputs into finished outputs through a series of production processes. The Production Manager is responsible for making sure that raw materials are provided and made into finished goods effectively. He or she must make sure that work is carried out smoothly, and must supervise procedures for making work more efficient and more enjoyable.
In a manufacturing company the production function may be split into five sub-functions:
• The production and planning department will set standards and targets for each section of the production process. The quantity and quality of products coming off a production line will be closely monitored. In businesses focusing on lean production, quality will be monitored by all employees at every stage of production, rather than at the end as is the case for businesses using a quality control approach.
• The purchasing department will be responsible for providing the materials, components and equipment required to keep the production process running smoothly. A vital aspect of this role is ensuring stocks arrive on time and to the right quality.
• The stores department will be responsible for stocking all the necessary tools, spares, raw materials and equipment required to service the manufacturing process. Where sourcing is unreliable, buffer stocks will need to be kept and the use of computerized stock control systems helps keep stocks at a minimal but necessary level for production to continue unhindered.
• The design and technical support department will be responsible for researching new products or modifications to existing ones, estimating costs for producing in different quantities and by using different methods. It will also be responsible for the design and testing of new product processes and product types, together with the development of prototypes through to the final product. The technical support department may also be
Responsible for work study and suggestions as to how working practices can be improved. The works department will be concerned with the manufacture of products. This will include the maintenance of the production line and other necessary repairs. The works department may also have responsibility for quality control and inspection.
B. QUALITY DEPARTMENT:
Quality department is one of the vital areas in BHEL. BHEL is quality oriented company. So this department plays very important role. The organization chart of Quality department is given below:
QUALITY CONTROL:
• Inspection of incoming material and in process activity.
• Identification, documentation after the deposition of non-conformities.
• Compliance of quality records related to product manufacture.
• Maintaining trace ability of items where needed.
• Acquisition of new instruments / updating of inspection of techniques to personnel usage.
QUALITY OBJECTIVE:
• Compliances to specifications, national /international standards and statuary regulations.
• Selection of vendors based upon organizational soundness, technical competence and quality system adequacy.
• Development and retaining of suppliers in order to ensure quality products, delivery and serve requirement.
• Pursuing continual improvement in quality of its products, services and performance through technology excellence, continuous leaving and retrospection.
• Development and nurture dedicated committed team of employees for achieving total customer satisfaction and business growth.
• Promote companywide quality through training and educational programs and ensure that quality policy is understood and followed across the organization.
C. COMMERCIAL DEPARTMENT :
ORGANIZATION AND RESPONSIBILITIES
This section details out the organization and responsibilities of COMMERCIAL DEPARTMENT. Organization chart and responsibilities are shown-
ACTIVITIES
• Section 1 – Order Receipt
• Section 2 – Post Contract Activities
• Section 3 – Support & Monitoring Activities
SECTION 1 : ORDER RECEIPT
This section deals with the receipt of order acceptances for valves and spares.
Valves Commercial of BHEL Trichy carries out all the pre contract activities for IVP BHEL, Goindwal. Commercial Goindwal will receive order acceptances for sale orders, GMS or order intimations for boiler orders and order intimation for spare orders from BHEL Trichy.
CE-Marking Orders: Valves Commercial of BHEL Trichy carries out all the pre contract activities for IVP BHEL, Goindwal. The orders are uniquely identified by BHEL Trichy and sent to IVP Goindwal. IVP Goindwal prefixes “CE” to the Order Acceptance No. forwarded by BHEL Trichy for internal references& monitoring.
SECTION 2 : POST CONTRACT ACTIVITIES
This section deals with the post contract activities of commercial.
Commercial Goindwal will:
• Maintain records of Order Acceptances (with Third Party Inspection) along with Purchase Order (if required), Quality Plan (other than BHEL’s standard Quality Plan), Design Change Note and amendments.
• Monitor customer priorities based on the inputs from Trichy and customer.
• Arrange contract review as & when orders are received from Trichy & follow up with valves commercial Trichy for resolving non-conformances/differences in contract and to ensure completeness of information/documents of contract.
• Have liaison with Quality, OPC, Engineering, Material Management, and Shipping & Finance and provide clarifications.
• Coordinate with Material Management, OPC and Production to update procurement and production status of major projects and customer requirements.
• Release commercial plan to OPC, MM & Production three months in advance.
• Verify dispatch documents.
• Forward relevant dispatch documents to Finance.
• Forward dispatch documents to consignee/customer and Trichy.
• Coordinate with transporters for expediting delivery of valves and rebooking from customer, wherever needed.
• Attend to customer correspondence and to reply in time.
• Receive amendments in system of order acceptances from Trichy and send the same thru’ e mail to OPC, Material Management, Quality.
• HEAD commercial will review the status of customer complaints once in a month and put up exceptional report to HOU.
D. FINANCE DEPARTMENT :
Finance and accounting department is one of the core departments of the industry. All the financial tasks and jobs are done in this department. Records of all financial transactions are handled by this department.
The taxation function includes two types of taxes. One is direct taxes and second is indirect taxes. The direct taxes include TDS and indirect taxes include Excise and sales tax. The finance department mainly deals with material management department in which main functions are purchase and sub-contracting. Other dealing departments are commercial departments, human resources department and production department.
E. HUMAN RESOURCE DEPARTMENT :
OBJECTIVES:
• Optimum utilization of human resources through matching individual and job requirement
• To identify the individual potential and placement matching to it
• To create a pool of competent personnel for future requirement
• To create an opportunity for growth and thereby enhance motivation of employees
• To cater to the organization future human resource needs
• To provide a mechanism for hiring right people
• Cost effective and faster mode of induction
• To insure proper fit of human potential and job requirement
• To link the organization with outer world
• To develop corporate relations of company
TRAINING AND DEVELOPMENT-
• To enhance devotion at workplace and also inculcate good thinking and feeling among the employees which result in place, harmony and efficient work.
• To retrain workmen on the various aspect of their working life for enhancing their knowledge and modifying their attitude as per the requirement of the organization.
• Need based training is being impacted by internal faculties as well as outside faculties.
• Executive development programmers are organized regularly
F. SUB-CONTRACTING DEPARTMENT :
ORGANIZATION AND RESPONSIBILITIES
• The integrated quality responsibilities are entrusted to the head of department/Section in charge along with authority to initiate to prevent non conformities.
• In charge/Sub-Contracting shall look after overall Sub-Contracting function and shall report to head/Operations.
• In Charge/Sub Contracting shall be assisted by two ETs, three FTAs, and technician in carrying out activities detailed.
• Organization chart of Sub Contracting department is shown below.
ACTIVITIES
EVALUATION, SELECTION AND PERFORMANCE MONITORING OF SUB-CONTRACTORS.
The performance rating of vendors shall be carried out by the Sub Contracting Dep’t and Quality Dep’t as per SP-04. The compiled data shall be presented to VRC-GW once a year by Sub Contracting Dep’t for evaluation purpose in the prescribed format.
VRC-GW will review the performance rating and shall communicate feedback on performance rating to the individual vendor in format SC:VRC:GW-06 even if performance is satisfactory i.e (60 & above out of 100). If the performance rating is below 60 (out of 100), it shall be taken as poor performance and this shall be communicated by Sub Contracting Dep’t. To same vendor in the same format SC:VRC:GW-06 for improving his performance. If the response is not satisfactory, the Sub contracting dep’t shall stop loading material to that firm till a satisfactory response is obtained. After receiving satisfactory reply, the performance of that vendor shall be monitored for next three months and a compiled report shall be framed by compiling performance monitoring data as per SP-04 for three months. If the rating is again below 60, VRC shall take action for delisting after taking approval from HOU as per format SC:VRC:GW-07.
The registration shall be carried out by sub contracting dep’t In order to have competitive vendors. The Supplier registration process can be categorized in the following stages:
• Information Stage
• Assessment Stage
• Enlistment Stage
RECEIPT OF PURCHASE REQUISITIONS
• All the requirements shall be generated by the system and action will be initiated according to Production Plan released by OPC and priority given by the system.
• Requirements shall be processed for offloading in according with rate contracts.
• Review the requirements for delivery commitments.
FLOATING ENQURIES
• In Charge. Sub Contracting Shall
• estimate the value for enquiry
• Select approved Sub contractor from the approved vendor Directory (Sub-contg.)
• Obtain approval from competent authority as per delegation of powers for issue of enquiries.
• Receive offers as per enquiry.
REVIEW OF OFFERS
• In-charge/sub-Contracting shall process the offers as per guidelines of purchase. Policy and for placement of order/rate contract on suitable bidders.
PLACEMENT OF SUB-CONTRACTING ORDER
• In-charge/sub-contracting shall
• Obtain approval of competent authority as per delegation of powers
• Obtain financial concurrence wherever required as per purchase policy.
• Distribute the rate contract/sub contracting purchase order to Sub Contractor
• The officer signing the rate Contract/Sub-Contracting purchase Order Shall Specify the period of rate contract & rate should be invited on per piece basis.
MATERIAL ISSUE AND RECEIPT
• Based on Sub- Contracting Purchase Order material shall be issued from main Store or Component Store by the in-charge stores.
• Stores in-charge will release the gate pass for the issued material and material will be received by Sub- Contractor.
• On processing at sub contractor’s end, the material/component shall be received at Component stores.
G. OPERATION PLANNING AND CONTROL (OPC) :
OPC department is responsible for preparing the monthly plan of unit and its successful execution. The organization structure of OP&C is as shown below;
ACTIVITIES
a. Preparation and distribution of Production Plan
• On receipt of Commercial Plan / Potential from Commercial department OP&C shall prepare Monthly Production Plan based upon criteria of delivery period, material availability and Stocking needs.
• The periodicity of release of Production Plan shall be increased if the need arises to meet specific delivery requirements or criticalities as indicated by Commercial department.
OP&C shall circulate Production Plan to the following:
• Head of Unit
• Head of Sub- Contracting
• Head of Production
• Head of Quality & Engineering
• Head Material Management
• Head of Commercial
b. Coordination for liquidation of Rework Orders
OP&C shall receive re-work order from Quality Control and co-ordinate for the liquidation of re-work either from sub-contracting or shop as per case.
c. Follow up with Sub Contracting Department
• OP&C shall co-ordinate and follow up with sub-contracting Department for timely liquidation of sub-contracted items.
• OP&C shall co-ordinate with sub-contracting for getting commitments and liquidation of hold ups against monthly production plan.
• OP&C shall participate in production review meetings and obtain the status of production plan and follow up with other depts. for removal of hold ups.
d. Preparation and attending Production review
• OP&C shall prepare the list for production review and attend production review meeting.
• OP&C shall highlight criticalities of orders and pursue for early liquidation of order.
1.3 NECESSITY OF VALVES
A valve is a device that regulates, directs or controls the flow of a fluid (gases, liquids, fluidized solids, or slurries) by opening, closing, or partially obstructing various passageways. Valves are technically valves fittings, but are usually discussed as separate category. In an open valve, fluid flows in a direction from higher pressure to lower pressure. The simplest, and very ancient, valve is simply freely hinged flap which drops to obstruct fluid (gas or liquid) flow in one direction, but is pushed open by flow in the opposite direction. This is called a check valve, as it prevents or “checks" the flow in one direction. Valves have many uses, including controlling water for Irrigation , industrial uses for controlling processes, residential uses such as on / off & pressure control to dish and clothes washers & taps in the home. Eveaero sol shave a tiny valve built in. Valves are also used in the military & transport sectors. Valves are found in virtually every industrial process, including water & sewage processing, mining, power generation, processing of oil, gas & petroleum, food manufacturing, chemical& plastic manufacturing and many other fields. People in developed nations use valves in their daily lives, including plumbing valves, such as taps for tap water , gas control valves on cookers, small valves fitted to washing machines and dishwashers , safety devices fitted to hot water systems , and poppet valves in car engines. In nature there are valves, for example one-way valves in veins controlling the blood circulation , & heart valves controlling the flow of blood in the chambers of the heart and maintaining the correct pumping action.
CHATER II
CLASSIFICATION OF VALVES
2.1 Globe Valve
2.2 Gate Valve
2.3 Flap Valve
2.4 Toa Valve
2.5 Production Range at IVP Plant Goindwal
2.1 GLOBE VALVE (RV & SV)
A Globe valve is a type of Valve used for regulating flow in a Piping, consisting of a movable disk-type element and a stationary ring seat in a generally spherical body Globe Valves are named for their spherical body shape with the two halves of the body being separated by an internal wikt: baffle. This has an opening that forms a seat onto which a movable plug can be screwed in to close (or shut) the valve. The plug is also called a disc or disk. In globe valves, the plug is connected to a stem which is operated by screw action in manual valves. Typically, automated valves use sliding stems. Automated globe valves have a smooth stem rather than Screw thread and are opened and closed by an Actuator assembly. When a globe valve is manually operated, the stem is turned by a hand wheel. Although globe valves in the past had the spherical bodies which gave them their name, many modern globe valves do not have much of a spherical shape. However, the term globe valve is still often used for valves that have such an internal mechanism. In Plumbing, valves with such a mechanism are also often called stop valves since they don't have the global appearance, but the term stop valve may refer to valves which are used to stop flow even when they have other mechanisms or designs.
Fig. 2.1 Globe Valve
Globe valves are used for applications requiring throttling and frequent operation. For example, globe valves or valves with a similar mechanism may be used as sampling valves, which are normally shut except when liquid samples are being taken. Since the baffle restricts flow, they're not recommended where full, unobstructed flow is required.
2.1.1 INFORMATION
Although globe valves in the past had the spherical bodies which gave them their name many modern globe valves do not have much of a spherical shape. However, the term globe is still often used for valves that have such an internal mechanism. In plumbing, valves with such a mechanism are also often called stop valves since they don't have the global appearance, but the term stop valve may refer to valves which are used to stop flow even when they have other mechanisms or designs. Globe valves are used for applications requiring throttling and frequent operation. For example, globe valves or valves with a similar mechanism may be used as sampling valves, which are normally shut except when liquid samples are being taken. Since the baffle restricts flow, they are not recommended where full, unobstructed flow is required.
2.1.2 PARTS OF A TYPICAL GLOBE VALVE v BODY
The body is the main pressure containing structure of the valve and the most easily identified as it forms the mass of the valve. It contains all of the valve's internal parts that will come in contact with the substance being controlled by the valve.
Fig. 2.2 RV or SV Body
The bonnet is connected to the body and provides the containment of the fluid, gas, or slurry that is being controlled. Globe valves are typically two-port valves, although three port valves are also produced mostly in straight-flow configuration. Ports are openings in the body for fluid flowing in or out. he two ports may be oriented straight across from each other or anywhere on the body, or oriented at an angle (such as a 90°). [Globe valves with ports at such an angle are called angle globe valves . Globe valves are mainly used for corrosive or high viscous fluids which solidify at room temperature. This is because straight valves are designed so that the outlet pipe is in line with the inlet pipe and
the fluid has a good chance of staying there in the case of horizontal piping. In the case of angle valves, the outlet pipe is directed towards the bottom. This allows the fluid to drain off. In turn, this prevents clogging and/or corrosion of the valve components over a period of time. A globe valve can also have a body in the shape of a "Y". This will allow the construction of the valve to be straight at the bottom as opposed to the conventional pot type construction (to arrange bottom seat) in case of other valves. This will again allow the fluid to pass through without difficulty and minimizes fluid clogging/corrosion in the long term.
v BONNET
Provides leak-proof closure for the valve body. The threaded section of stem goes through a hole with matching threads in the bonnet. Globe valves may have a screw-in, union, or bolted bonnet. Screw-in bonnet is the simplest bonnet, offering a durable, pressure-tight seal. Union bonnet is suitable for applications requiring frequent inspection or cleaning.
Fig. 2.3 Bonnet
It also gives the body added strength. A bonnet attached with bolts is used for larger or higher pressure applications. Bonnets also contain the packing, which is a wearable material that maintains the seal between the bonnet and the stem during valve cycling operations
v PLUG OR DISC (DISK)
The closure member of the valve. Plugs are connected to the stem which is slid or screwed up or down to throttle the flow. Plugs are typically of the balance or unbalanced type. Unbalanced plugs are solid and are used with smaller valves or with low pressure drops across the valve. The advantages are simpler design, with one possible leak path at the seat and usually lower cost.
Fig.2.4 RV DISK
The disadvantages are the limited size; with a large unbalanced plug the forces needed to seat and hold the flow off become impractical. Balanced plugs have holes through the plug. Advantages include easier shut off as the plug does not have to overcome static forces. However, a second leak path is created between the plug and the cage, cost is generally higher.
Fig. 2.5 SV DISK
v STEM
The stem serves as a connector from the actuator to the inside of the valve and transmits this actuation force. Stems are either smooth for actuator controlled valves or threaded for manual valves. The smooth stems are surrounded by packing material to prevent leaking material from the valve. This packing is a wear material and will have to be replaced during maintenance. With a smooth stem the ends are threaded to allow connection to the plug and the actuator.
Fig. 2.6 Stem
The stem must not only withstand a large amount of compression force during valve closure, but also have high tensile strength during valve opening. In addition, the stem must be very straight, or have low run-out, in order to ensure good valve closure. This minimum run-out also minimizes wear of the packing contained in the bonnet, which provides the seal against leakage. The stem may be provided with a shroud over the packing nut to prevent foreign bodies entering the packing material, which would accelerate wear. v SEAT RING
The seat ring provides a stable, uniform and replaceable shut off surface. Seat rings are usually held in place by pressure from the fastening of the bonnet to the top of the body. This pushes the cage down on the lip of the seat ring and holds it firmly to the body of the valve.
Seat rings may also be threaded and screwed into a thread cut in the same area of the body. However this method makes removal of the seat ring during maintenance difficult if not impossible. Seat rings are also typically bevelled at the seating surface to allow for some guiding during the final stages of closing the valve.
Fig. 2.7 Seat Ring
Economical globe valves or stop valves with a similar mechanism used in plumbing often have a Rubber Washer at the bottom of the disc for the seating surface, so that rubber can be compressed against the seat to form a leak-tight seal when shut.
Many globe valves have a class rating that corresponds to the pressure specifications of ANSI 16.34. Bibcock and Sillcock are variations of globe or stop valves used in plumbing. Needle valve are variations of globe valves where instead of a separate attached disc piece, the internal end of the stem is conically tapered to act as the disc to fit into a matching seat for fine flow adjustment
Other different types of valve usually are called globe style valves because of the shape of the body or the way of closure of the disk. As an example typical swing check valves could be called globe type.
v HANDWHEEL
The spoked hand wheel is fabricated from steel pipe. The hub has a square hole for coupling with the stem, and for large sizes the hub is coupled with the yoke sleeve by means of a tongue like gate valve
CHATER I
INTRODUCTION
1.1 Introduction of Company
1.2 Intradepartmental exposure:
1.3 Necessity of Valves
1.1 INTRODUCTION
BHEL – IVP, GOINDWAL SAHIB
BHELis the largest engineering and manufacturing enterprise in India in the energy-related/infrastructure sector, today.BHEL was established more than 40 years ago, ushering in the indigenous Heavy Electrical Equipment industry in India - a dream that has been more than realized with a well-recognized track record of performance. The company has been earning profits continuously since 1971-72 and paying dividends since 1976-77.
BHELmanufactures over 180 products under 30 major product groups and caters to core sectors of the Indian Economy viz., Power Generation & Transmission, Industry, Transportation, Renewable Energy, etc. The wide network ofBHEL's 14 manufacturing divisions, four Power Sector regional centers, over 100 project sites, eight service centers, 18 regional offices and one subsidiary enables the Company to promptly serve its customers and provide them with suitable products, systems and services -- efficiently and at competitive prices. The high level of quality & reliability of its products is due to the emphasis on design, engineering and manufacturing to international standards by acquiring and adapting some of the best technologies from leading companies in the world, together with technologies developed in its own R&D centers.
BHELhas acquired certifications to Quality Management Systems (ISO 9001), Environmental Management Systems (ISO 14001) and Occupational Health & Safety Management Systems (OHSAS 18001) and is also well on its journey towards Total Quality Management.
Goindwal Sahib is a historic and revered town founded by the third Sikh Guru Amar Das Ji in 1546 A.D., situated on Sher Shah Suri marg running from Kolkata to Peshawar. In the year 1979, the central government decided to set up first nucleus industrial tour at Goindwal Sahib.
In line policy declared by govt. of India in July 1980,for the development of nucleus industrial tours, BHEL management took decision to establish industrial valve plant at Goindwal Sahib with the initial capital investment of Rs. 3 crore. Industrial valve plant is a part of BHEL Trichy complex. It is one of the major complexes of BHEL and comprising of high pressure boiling plant(HPBP), seamless steel tube plant(SSTP), piping centre of Chennai, Boiler auxiliaries plant (BAP) at Ranipat and industrial valve plant(IVP) at Goindwal. The complex is headed by executive director who is the member of the management committee and reports the company’s CMD.
The present manufacturing range of valves at IVP, Goindwal covers 2’’ to 24’’ valves with different material specifications from carbon steel to stainless steel with a variety of special features like motorized/geared operation, limit switches arrangement, indicator arrangement, lock/chain wheel arrangement and other required by customer.
1.2 INTRADEPARTMENTAL EXPOSURE:
A. PRODUCTION DEPARTMENT
Production is the functional area responsible for turning inputs into finished outputs through a series of production processes. The Production Manager is responsible for making sure that raw materials are provided and made into finished goods effectively. He or she must make sure that work is carried out smoothly, and must supervise procedures for making work more efficient and more enjoyable.
In a manufacturing company the production function may be split into five sub-functions:
• The production and planning department will set standards and targets for each section of the production process. The quantity and quality of products coming off a production line will be closely monitored. In businesses focusing on lean production, quality will be monitored by all employees at every stage of production, rather than at the end as is the case for businesses using a quality control approach.
• The purchasing department will be responsible for providing the materials, components and equipment required to keep the production process running smoothly. A vital aspect of this role is ensuring stocks arrive on time and to the right quality.
• The stores department will be responsible for stocking all the necessary tools, spares, raw materials and equipment required to service the manufacturing process. Where sourcing is unreliable, buffer stocks will need to be kept and the use of computerized stock control systems helps keep stocks at a minimal but necessary level for production to continue unhindered.
• The design and technical support department will be responsible for researching new products or modifications to existing ones, estimating costs for producing in different quantities and by using different methods. It will also be responsible for the design and testing of new product processes and product types, together with the development of prototypes through to the final product. The technical support department may also be
Responsible for work study and suggestions as to how working practices can be improved. The works department will be concerned with the manufacture of products. This will include the maintenance of the production line and other necessary repairs. The works department may also have responsibility for quality control and inspection.
B. QUALITY DEPARTMENT:
Quality department is one of the vital areas in BHEL. BHEL is quality oriented company. So this department plays very important role. The organization chart of Quality department is given below:
QUALITY CONTROL:
• Inspection of incoming material and in process activity.
• Identification, documentation after the deposition of non-conformities.
• Compliance of quality records related to product manufacture.
• Maintaining trace ability of items where needed.
• Acquisition of new instruments / updating of inspection of techniques to personnel usage.
QUALITY OBJECTIVE:
• Compliances to specifications, national /international standards and statuary regulations.
• Selection of vendors based upon organizational soundness, technical competence and quality system adequacy.
• Development and retaining of suppliers in order to ensure quality products, delivery and serve requirement.
• Pursuing continual improvement in quality of its products, services and performance through technology excellence, continuous leaving and retrospection.
• Development and nurture dedicated committed team of employees for achieving total customer satisfaction and business growth.
• Promote companywide quality through training and educational programs and ensure that quality policy is understood and followed across the organization.
C. COMMERCIAL DEPARTMENT :
ORGANIZATION AND RESPONSIBILITIES
This section details out the organization and responsibilities of COMMERCIAL DEPARTMENT. Organization chart and responsibilities are shown-
ACTIVITIES
• Section 1 – Order Receipt
• Section 2 – Post Contract Activities
• Section 3 – Support & Monitoring Activities
SECTION 1 : ORDER RECEIPT
This section deals with the receipt of order acceptances for valves and spares.
Valves Commercial of BHEL Trichy carries out all the pre contract activities for IVP BHEL, Goindwal. Commercial Goindwal will receive order acceptances for sale orders, GMS or order intimations for boiler orders and order intimation for spare orders from BHEL Trichy.
CE-Marking Orders: Valves Commercial of BHEL Trichy carries out all the pre contract activities for IVP BHEL, Goindwal. The orders are uniquely identified by BHEL Trichy and sent to IVP Goindwal. IVP Goindwal prefixes “CE” to the Order Acceptance No. forwarded by BHEL Trichy for internal references& monitoring.
SECTION 2 : POST CONTRACT ACTIVITIES
This section deals with the post contract activities of commercial.
Commercial Goindwal will:
• Maintain records of Order Acceptances (with Third Party Inspection) along with Purchase Order (if required), Quality Plan (other than BHEL’s standard Quality Plan), Design Change Note and amendments.
• Monitor customer priorities based on the inputs from Trichy and customer.
• Arrange contract review as & when orders are received from Trichy & follow up with valves commercial Trichy for resolving non-conformances/differences in contract and to ensure completeness of information/documents of contract.
• Have liaison with Quality, OPC, Engineering, Material Management, and Shipping & Finance and provide clarifications.
• Coordinate with Material Management, OPC and Production to update procurement and production status of major projects and customer requirements.
• Release commercial plan to OPC, MM & Production three months in advance.
• Verify dispatch documents.
• Forward relevant dispatch documents to Finance.
• Forward dispatch documents to consignee/customer and Trichy.
• Coordinate with transporters for expediting delivery of valves and rebooking from customer, wherever needed.
• Attend to customer correspondence and to reply in time.
• Receive amendments in system of order acceptances from Trichy and send the same thru’ e mail to OPC, Material Management, Quality.
• HEAD commercial will review the status of customer complaints once in a month and put up exceptional report to HOU.
D. FINANCE DEPARTMENT :
Finance and accounting department is one of the core departments of the industry. All the financial tasks and jobs are done in this department. Records of all financial transactions are handled by this department.
The taxation function includes two types of taxes. One is direct taxes and second is indirect taxes. The direct taxes include TDS and indirect taxes include Excise and sales tax. The finance department mainly deals with material management department in which main functions are purchase and sub-contracting. Other dealing departments are commercial departments, human resources department and production department.
E. HUMAN RESOURCE DEPARTMENT :
OBJECTIVES:
• Optimum utilization of human resources through matching individual and job requirement
• To identify the individual potential and placement matching to it
• To create a pool of competent personnel for future requirement
• To create an opportunity for growth and thereby enhance motivation of employees
• To cater to the organization future human resource needs
• To provide a mechanism for hiring right people
• Cost effective and faster mode of induction
• To insure proper fit of human potential and job requirement
• To link the organization with outer world
• To develop corporate relations of company
TRAINING AND DEVELOPMENT-
• To enhance devotion at workplace and also inculcate good thinking and feeling among the employees which result in place, harmony and efficient work.
• To retrain workmen on the various aspect of their working life for enhancing their knowledge and modifying their attitude as per the requirement of the organization.
• Need based training is being impacted by internal faculties as well as outside faculties.
• Executive development programmers are organized regularly
F. SUB-CONTRACTING DEPARTMENT :
ORGANIZATION AND RESPONSIBILITIES
• The integrated quality responsibilities are entrusted to the head of department/Section in charge along with authority to initiate to prevent non conformities.
• In charge/Sub-Contracting shall look after overall Sub-Contracting function and shall report to head/Operations.
• In Charge/Sub Contracting shall be assisted by two ETs, three FTAs, and technician in carrying out activities detailed.
• Organization chart of Sub Contracting department is shown below.
ACTIVITIES
EVALUATION, SELECTION AND PERFORMANCE MONITORING OF SUB-CONTRACTORS.
The performance rating of vendors shall be carried out by the Sub Contracting Dep’t and Quality Dep’t as per SP-04. The compiled data shall be presented to VRC-GW once a year by Sub Contracting Dep’t for evaluation purpose in the prescribed format.
VRC-GW will review the performance rating and shall communicate feedback on performance rating to the individual vendor in format SC:VRC:GW-06 even if performance is satisfactory i.e (60 & above out of 100). If the performance rating is below 60 (out of 100), it shall be taken as poor performance and this shall be communicated by Sub Contracting Dep’t. To same vendor in the same format SC:VRC:GW-06 for improving his performance. If the response is not satisfactory, the Sub contracting dep’t shall stop loading material to that firm till a satisfactory response is obtained. After receiving satisfactory reply, the performance of that vendor shall be monitored for next three months and a compiled report shall be framed by compiling performance monitoring data as per SP-04 for three months. If the rating is again below 60, VRC shall take action for delisting after taking approval from HOU as per format SC:VRC:GW-07.
The registration shall be carried out by sub contracting dep’t In order to have competitive vendors. The Supplier registration process can be categorized in the following stages:
• Information Stage
• Assessment Stage
• Enlistment Stage
RECEIPT OF PURCHASE REQUISITIONS
• All the requirements shall be generated by the system and action will be initiated according to Production Plan released by OPC and priority given by the system.
• Requirements shall be processed for offloading in according with rate contracts.
• Review the requirements for delivery commitments.
FLOATING ENQURIES
• In Charge. Sub Contracting Shall
• estimate the value for enquiry
• Select approved Sub contractor from the approved vendor Directory (Sub-contg.)
• Obtain approval from competent authority as per delegation of powers for issue of enquiries.
• Receive offers as per enquiry.
REVIEW OF OFFERS
• In-charge/sub-Contracting shall process the offers as per guidelines of purchase. Policy and for placement of order/rate contract on suitable bidders.
PLACEMENT OF SUB-CONTRACTING ORDER
• In-charge/sub-contracting shall
• Obtain approval of competent authority as per delegation of powers
• Obtain financial concurrence wherever required as per purchase policy.
• Distribute the rate contract/sub contracting purchase order to Sub Contractor
• The officer signing the rate Contract/Sub-Contracting purchase Order Shall Specify the period of rate contract & rate should be invited on per piece basis.
MATERIAL ISSUE AND RECEIPT
• Based on Sub- Contracting Purchase Order material shall be issued from main Store or Component Store by the in-charge stores.
• Stores in-charge will release the gate pass for the issued material and material will be received by Sub- Contractor.
• On processing at sub contractor’s end, the material/component shall be received at Component stores.
G. OPERATION PLANNING AND CONTROL (OPC) :
OPC department is responsible for preparing the monthly plan of unit and its successful execution. The organization structure of OP&C is as shown below;
ACTIVITIES
a. Preparation and distribution of Production Plan
• On receipt of Commercial Plan / Potential from Commercial department OP&C shall prepare Monthly Production Plan based upon criteria of delivery period, material availability and Stocking needs.
• The periodicity of release of Production Plan shall be increased if the need arises to meet specific delivery requirements or criticalities as indicated by Commercial department.
OP&C shall circulate Production Plan to the following:
• Head of Unit
• Head of Sub- Contracting
• Head of Production
• Head of Quality & Engineering
• Head Material Management
• Head of Commercial
b. Coordination for liquidation of Rework Orders
OP&C shall receive re-work order from Quality Control and co-ordinate for the liquidation of re-work either from sub-contracting or shop as per case.
c. Follow up with Sub Contracting Department
• OP&C shall co-ordinate and follow up with sub-contracting Department for timely liquidation of sub-contracted items.
• OP&C shall co-ordinate with sub-contracting for getting commitments and liquidation of hold ups against monthly production plan.
• OP&C shall participate in production review meetings and obtain the status of production plan and follow up with other depts. for removal of hold ups.
d. Preparation and attending Production review
• OP&C shall prepare the list for production review and attend production review meeting.
• OP&C shall highlight criticalities of orders and pursue for early liquidation of order.
1.3 NECESSITY OF VALVES
A valve is a device that regulates, directs or controls the flow of a fluid (gases, liquids, fluidized solids, or slurries) by opening, closing, or partially obstructing various passageways. Valves are technically valves fittings, but are usually discussed as separate category. In an open valve, fluid flows in a direction from higher pressure to lower pressure. The simplest, and very ancient, valve is simply freely hinged flap which drops to obstruct fluid (gas or liquid) flow in one direction, but is pushed open by flow in the opposite direction. This is called a check valve, as it prevents or “checks" the flow in one direction. Valves have many uses, including controlling water for Irrigation , industrial uses for controlling processes, residential uses such as on / off & pressure control to dish and clothes washers & taps in the home. Eveaero sol shave a tiny valve built in. Valves are also used in the military & transport sectors. Valves are found in virtually every industrial process, including water & sewage processing, mining, power generation, processing of oil, gas & petroleum, food manufacturing, chemical& plastic manufacturing and many other fields. People in developed nations use valves in their daily lives, including plumbing valves, such as taps for tap water , gas control valves on cookers, small valves fitted to washing machines and dishwashers , safety devices fitted to hot water systems , and poppet valves in car engines. In nature there are valves, for example one-way valves in veins controlling the blood circulation , & heart valves controlling the flow of blood in the chambers of the heart and maintaining the correct pumping action.
CHATER II
CLASSIFICATION OF VALVES
2.1 Globe Valve
2.2 Gate Valve
2.3 Flap Valve
2.4 Toa Valve
2.5 Production Range at IVP Plant Goindwal
2.1 GLOBE VALVE (RV & SV)
A Globe valve is a type of Valve used for regulating flow in a Piping, consisting of a movable disk-type element and a stationary ring seat in a generally spherical body Globe Valves are named for their spherical body shape with the two halves of the body being separated by an internal wikt: baffle. This has an opening that forms a seat onto which a movable plug can be screwed in to close (or shut) the valve. The plug is also called a disc or disk. In globe valves, the plug is connected to a stem which is operated by screw action in manual valves. Typically, automated valves use sliding stems. Automated globe valves have a smooth stem rather than Screw thread and are opened and closed by an Actuator assembly. When a globe valve is manually operated, the stem is turned by a hand wheel. Although globe valves in the past had the spherical bodies which gave them their name, many modern globe valves do not have much of a spherical shape. However, the term globe valve is still often used for valves that have such an internal mechanism. In Plumbing, valves with such a mechanism are also often called stop valves since they don't have the global appearance, but the term stop valve may refer to valves which are used to stop flow even when they have other mechanisms or designs.
Fig. 2.1 Globe Valve
Globe valves are used for applications requiring throttling and frequent operation. For example, globe valves or valves with a similar mechanism may be used as sampling valves, which are normally shut except when liquid samples are being taken. Since the baffle restricts flow, they're not recommended where full, unobstructed flow is required.
2.1.1 INFORMATION
Although globe valves in the past had the spherical bodies which gave them their name many modern globe valves do not have much of a spherical shape. However, the term globe is still often used for valves that have such an internal mechanism. In plumbing, valves with such a mechanism are also often called stop valves since they don't have the global appearance, but the term stop valve may refer to valves which are used to stop flow even when they have other mechanisms or designs. Globe valves are used for applications requiring throttling and frequent operation. For example, globe valves or valves with a similar mechanism may be used as sampling valves, which are normally shut except when liquid samples are being taken. Since the baffle restricts flow, they are not recommended where full, unobstructed flow is required.
2.1.2 PARTS OF A TYPICAL GLOBE VALVE v BODY
The body is the main pressure containing structure of the valve and the most easily identified as it forms the mass of the valve. It contains all of the valve's internal parts that will come in contact with the substance being controlled by the valve.
Fig. 2.2 RV or SV Body
The bonnet is connected to the body and provides the containment of the fluid, gas, or slurry that is being controlled. Globe valves are typically two-port valves, although three port valves are also produced mostly in straight-flow configuration. Ports are openings in the body for fluid flowing in or out. he two ports may be oriented straight across from each other or anywhere on the body, or oriented at an angle (such as a 90°). [Globe valves with ports at such an angle are called angle globe valves . Globe valves are mainly used for corrosive or high viscous fluids which solidify at room temperature. This is because straight valves are designed so that the outlet pipe is in line with the inlet pipe and
the fluid has a good chance of staying there in the case of horizontal piping. In the case of angle valves, the outlet pipe is directed towards the bottom. This allows the fluid to drain off. In turn, this prevents clogging and/or corrosion of the valve components over a period of time. A globe valve can also have a body in the shape of a "Y". This will allow the construction of the valve to be straight at the bottom as opposed to the conventional pot type construction (to arrange bottom seat) in case of other valves. This will again allow the fluid to pass through without difficulty and minimizes fluid clogging/corrosion in the long term.
v BONNET
Provides leak-proof closure for the valve body. The threaded section of stem goes through a hole with matching threads in the bonnet. Globe valves may have a screw-in, union, or bolted bonnet. Screw-in bonnet is the simplest bonnet, offering a durable, pressure-tight seal. Union bonnet is suitable for applications requiring frequent inspection or cleaning.
Fig. 2.3 Bonnet
It also gives the body added strength. A bonnet attached with bolts is used for larger or higher pressure applications. Bonnets also contain the packing, which is a wearable material that maintains the seal between the bonnet and the stem during valve cycling operations
v PLUG OR DISC (DISK)
The closure member of the valve. Plugs are connected to the stem which is slid or screwed up or down to throttle the flow. Plugs are typically of the balance or unbalanced type. Unbalanced plugs are solid and are used with smaller valves or with low pressure drops across the valve. The advantages are simpler design, with one possible leak path at the seat and usually lower cost.
Fig.2.4 RV DISK
The disadvantages are the limited size; with a large unbalanced plug the forces needed to seat and hold the flow off become impractical. Balanced plugs have holes through the plug. Advantages include easier shut off as the plug does not have to overcome static forces. However, a second leak path is created between the plug and the cage, cost is generally higher.
Fig. 2.5 SV DISK
v STEM
The stem serves as a connector from the actuator to the inside of the valve and transmits this actuation force. Stems are either smooth for actuator controlled valves or threaded for manual valves. The smooth stems are surrounded by packing material to prevent leaking material from the valve. This packing is a wear material and will have to be replaced during maintenance. With a smooth stem the ends are threaded to allow connection to the plug and the actuator.
Fig. 2.6 Stem
The stem must not only withstand a large amount of compression force during valve closure, but also have high tensile strength during valve opening. In addition, the stem must be very straight, or have low run-out, in order to ensure good valve closure. This minimum run-out also minimizes wear of the packing contained in the bonnet, which provides the seal against leakage. The stem may be provided with a shroud over the packing nut to prevent foreign bodies entering the packing material, which would accelerate wear. v SEAT RING
The seat ring provides a stable, uniform and replaceable shut off surface. Seat rings are usually held in place by pressure from the fastening of the bonnet to the top of the body. This pushes the cage down on the lip of the seat ring and holds it firmly to the body of the valve.
Seat rings may also be threaded and screwed into a thread cut in the same area of the body. However this method makes removal of the seat ring during maintenance difficult if not impossible. Seat rings are also typically bevelled at the seating surface to allow for some guiding during the final stages of closing the valve.
Fig. 2.7 Seat Ring
Economical globe valves or stop valves with a similar mechanism used in plumbing often have a Rubber Washer at the bottom of the disc for the seating surface, so that rubber can be compressed against the seat to form a leak-tight seal when shut.
Many globe valves have a class rating that corresponds to the pressure specifications of ANSI 16.34. Bibcock and Sillcock are variations of globe or stop valves used in plumbing. Needle valve are variations of globe valves where instead of a separate attached disc piece, the internal end of the stem is conically tapered to act as the disc to fit into a matching seat for fine flow adjustment
Other different types of valve usually are called globe style valves because of the shape of the body or the way of closure of the disk. As an example typical swing check valves could be called globe type.
v HANDWHEEL
The spoked hand wheel is fabricated from steel pipe. The hub has a square hole for coupling with the stem, and for large sizes the hub is coupled with the yoke sleeve by means of a tongue like gate valve