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VIKASH KULSHRESTHA

From: Sriram B

Sent: 06 April 2016 21:58

To: Manivasakan G; Gopinath D; Srinivasan A V; Udaya Kumar K; Elankumaran S

Cc: Hari K S; Karthikeyan S; Ravichandran M A; M S Rajaraman; Shunmugavel H; V

Ramasubramanian; VIKASH KULSHRESTHA; Sathish Kumar C

Subject: RE: Operability Issue in 2"/4"/5"/8" Butterfly valve supplied to TATA MOTORS A/c

Rajdeep- Urgent

Attachments: MOM- Malfunctioning of Butterfly valve in CED Line Improvement project

Dear All,

This has further to the trailing mail, as requested today to Tata Motors I have dismantled 3nos of valves - 4”, 5” & 8”

valves the detailed observation here as under:-

1. Size:8” – 1No( Pneumatic actuator), 8” SAP NO: 110003097 Class: PN10, Location: UF Spray system,

operation on: Apr15, Line Pr:Less than 2bar, Temp: Ambient, Line Media: Ultrafilterate, Frequency of

operation: 200-240times/day.

The valve was observed un-operating, due to shaft free from disc. We dismantled the valve &noticed that

shaft & disc slot got sheared.

Since, frequent operation are nearly 200- 240 times/day. So, kindly check at our end also Parellely I

requested M/s ‘Rajdeep to provide actuator details for your reference Since we supplied only bare valves.

2. Size:4”- 1No , Class: PN10, Location: UF feed line ( delivery of UF Feed bag filters) , operation on: Apr15,

Line Pr: Less than 5 bar, Temp: Ambient, Line Media: CED paint( Mixture of DM water & paint).Frequency

of operation: 2-3 Times/week.

The valve was observed un-operating, due to shaft free from disc. After dismantling, grooved pin on flow

lever was observed in damaged condition.

After changing the available pin at site, it was noticed that valves are operating but not getting fully closed.

Also try to close without lever by applied wrench but no improvement. Looking to the site situation unable

Nearly 30% top shaft

of bottom portion

got sheared

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to check detaily . So, need to be analyse at our end. But presently told to customer that it may get resolved

by replacing with new grooved pin & flow lever.

3. Size:5”- 1No , Class: PN10,SAP NO: 110001125Location: UF feed line, operation on: Apr15, Line Pr: Less

than 5 bar, Temp: Ambient, Line Media: CED paint( Mixture of DM water & paint).Frequency of

operation:1Times/3 Months.

The valve was observed un-operating, due to shaft free from disc. After dismantling, grooved pin on flow

lever was observed in damaged condition.

After changing the available pin at site, it was noticed that valves are operating but not getting fully closed.

LTV suggests that failure of grooved pin is the probable reason for valve failure & valve not getting fully

closed. Also try to close without lever by applied wrench but no improvement. Looking to the site situation

unable to check detaily. So, need to be analyse at our premises further. But presently told to customer that

it may get resolved by replacing with new grooved pin & flow lever.

4. Size:2” – 1No, Class: PN10, SAP No: 110003986 Location: UF circulation system, operation on: Apr15, Line

Pr: Less than 2bar, Temp: Ambient, Line Media: Ultra Filtrate, Frequency of operation: 2 times/week

The valve was reported un-operating, due to shaft free from disc M/s Tata Motors told that Teflon tapes are

rolled on shaft square drive portion & assembled on disc for further operation (make shift arrangement to

run the production). Since it was in running process line unable to check internal parts.

Note: Due to this continuous failure customer was totally disappointed & consider to the site situation I was

not made any MOM. (Attached mail from customer feedback against the drafted MOM pg no:2 for your

reference).

I will ask Rajdeep to replace these valves from their stock & problematic valves will be send back to our

premises for further RCA purpose & arrange for correction action plan for balance valves on priority

basis.

Damaged

grooved pin.

Stem square slots

found ok.

3

Regards,

Sriram.

From: VIKASH KULSHRESTHA

Sent: 06 April 2016 09:14 To: Manivasakan G; Gopinath D; Srinivasan A V; Udaya Kumar K; Elankumaran S

Cc: Hari K S; Karthikeyan S; Ravichandran M A; M S Rajaraman; Sriram B; Shunmugavel H; V Ramasubramanian Subject: RE: Operability Issue in 2"/4"/5"/8" Butterfly valve supplied to TATA MOTORS A/c Rajdeep- Urgent

Pl review below and advise before it goes out of our hand.

Sriram is available at site today.

Regards,

Vikash Kulshrestha

From: Sriram B

Sent: 05 April 2016 21:08

To: Manivasakan G; Gopinath D Cc: Srinivasan A V; VIKASH KULSHRESTHA; Udaya Kumar K; Hari K S; Karthikeyan S; Ravichandran M A; M S

Rajaraman

Subject: Operability Issue in 2"/4"/5"/8" Butterfly valve supplied to TATA MOTORS A/c Rajdeep.

Dear Mani/ Gopinath,

This refers to the trailing mail, self visited to M/s Tata Motors , the detailed observation here as under:

Nature of complaint: Operability Issue.

Valve Type: Butterfly valve, Line Media: Water , Line pressure/Temp: 1.5 bar & Ambient, Operation on: Apr- May15.

Sizes: 2”PN10 – 1 No, Frequency of operation: weekly once/twice times. Problem faced on: Feb end, 4”/PN10 –

1No, problem faced on: Apr 1st

. Frequency of operation: Weekly once/twice times.

5”/PN10 – 1No , Frequency of operation, problem Faced on: Apr1st Weekly Once/Twice times. 8” /PN10 –

1No( Pneumatic Actuated) 100- 120 times / Day problem faced on Jan end.

In 4” &8” valve was observed that stem is rotating freely from shaft. Tried to check the internal parts but customer

not agreed to carried any service job at their end. Might be clearance fit between bearing/stem or bearing got worn

out.

In 2” valve customer has done that rolled more Teflon tape on stem ( square portion) & inserted on disc for

operating the valve. Due to this problem production loss was faced.

In 5” valve noticed that flow lever was rotating freely after taken out the grooved pin in lever noticed is was in-

damaged condition ( Attached Photo).

Sap details: 2” – 110003986 & 8” –110003097 about 4” & 5” will be send you the details soon.

Because of similar problem facing continuously customer was totally disappointed & strictly advise me to taken back

all installed valves.

Tomorrow again am requesting to customer for sending these valves to our plant for your RCA purpose & Parellely

we need to give proper solution for balanced supplied valves.

Regards,

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Sriram

From: Sriram B

Sent: 04 April 2016 15:00

To: Udaya Kumar K Cc: Srinivasan A V; VIKASH KULSHRESTHA

Subject: FW: Malfunctioning of 5 inch Butterfly valve of UF System, in CED Line Improvement project Importance: High

Dear Udaykumar,

As discussed, pl refer the serious trailing mail from M/s Tata Motors – Jamshedpur regarding the damages of lever

pins in flow control BFV.

2” – 1No ( SAP No: 110003986), 5” – 1No & 8” – 1no ( SAP No:110003097).

Self-plan a visit tomorrow to check the problem & have a meeting with Tata Motors higher-up. So, could pl provide

material specification, pin dimension details( drawings) for above valves for my reference.

Regards,

Sriram

From: Anand Shah [mailto:[email protected]]

Sent: Saturday, April 02, 2016 5:33 PM To: Sriram B

Cc: VIKASH KULSHRESTHA; [email protected]; M S Rajaraman Subject: FW: Malfunctioning of 5 inch Butterfly valve of UF System, in CED Line Improvement project

Importance: High

Dear Mr Sriram, 3/4/16

Refer to our telephonic discussion a few minutes back.

You are aware of the email ids / mob nos of the key persons in Tata Motors – J’pur / Plustech – Pune.

Request you to promptly send an email with the suitable earliest date for visit – wherein you will sort out both the

complaints ( the old case + the fresh case – I just received a few minutes back). The details of the new case are also

mentioned in the below email by the customer.

The Dnote details / complaint registration of the same would be done by our person on Monday since he is currently

involved in stock taking.

Your fast response on the same will be highly appreciated.

Thanks and Regards,

Anand D Shah

(Director)

5

Mob : 98500 48585 Ph./ Fax : 020-2439373

CIN – U51503PN1993PTC017927

-----------------------------------------------------------------

From: Dinesh Adiga [mailto:[email protected]]

Sent: 02 April 2016 16:20

To: [email protected]

Subject: FW: Malfunctioning of 5 inch Butterfly valve of UF System, in CED Line Improvement project

Importance: High

Most Urgent please

Dear Mr. Shah,

This has become a very serious issues a quick action is very urgently required.

Please take a quick action & resolve this issue.

Regards,

Dinesh Adiga

From: [email protected] [mailto:[email protected]]

Sent: 02 April 2016 16:10

To: Dinesh Adiga Cc: Kiran Khatake; [email protected]; Jayshankar Mishra; Rajesh Pillai; [email protected];

[email protected]; [email protected]; [email protected]

Subject: Malfunctioning of 5 inch Butterfly valve of UF System, in CED Line Improvement project Importance: High

Dear Sir,

As discussed, another Butterfly valve ( 3rd

in a row) has been malfunctioned yesterday. A 5 inch Butterfly

valve at Inlet to demister, was observed to malfunction when Chemical cleaning process of Membranes

was going on.

This series of Malfunctioning of valves is very serious concern & needs your immediate intervention.

Please arrange to send L & T person to site immediately to analyse the Root cause of the problem &

replace the damaged ones. Kindly ensure to send some senior person from L & T , for such a serious

concern.

Regards,

Deepein Ratra


Sent: Thursday, March 31, 2016 4:35 PM

To: Jaywant Jamdade; Jayshankar Mishra

Cc: Dinesh Adiga; Kiran Khatake; Devendra Natekar; [email protected] Subject: RE: Malfunctioning of 2 inch Butterfly valve of UF System, in CED Line Improvement project

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Dear Mr. Jaywant,

As discussed, the Plant will be closed tomorrow. Request you to kindly inform at least a day in advance about such

plans.

However, as discussed in the morning you can plan to arrange the visit of L & T representative on coming Monday i.e

4th

March-16.

Kindly confirm.

Regards,

Deepein Ratra

From: Jaywant Jamdade [mailto:[email protected]]

Sent: Thursday, March 31, 2016 12:14 PM

To: Jayshankar Mishra <[email protected]>; DEEPEIN RATRA [ CENT. PLANNING , Jamshedpur Works ]

<[email protected]>

Cc: Dinesh Adiga <[email protected]>; Kiran Khatake <[email protected]>; Devendra Natekar

<[email protected]>; [email protected]; [email protected]; 'Anand Shah'

<[email protected]>; Rajdeep,Anil Kankal <[email protected]>; 'Rajdeep Valve'

<[email protected]>


Dear Sir,

Please find below trailing mail regarding L & T Person visit at M/s. TATA Motors Limited, Jamshedpur on Tomorrow,

01.04.2016. Contact details are as per below. Please arrange to remove faulty valves for checking at L & T R & D

Dept.

CC : Mr. Sriram B,

Please note below contact person details at M/s. TATA Motors Ltd., Jamshedpur.

1. From Plustech Systems : Mr. Jayshankar Mishra ( 08809333531 / 09225600040 )

2. From M/s. TATA Motors – Mr. Deepein Ratra ( 09234686750 )

Please contact with him.

With Best Regards,

Jaywant Jamdade

For Plustech Systems & Solutions (P) Ltd.

Contact No. : 09225600031

From: Anil Kankal [mailto:[email protected]]

Sent: Thursday, March 31, 2016 9:37 AM

To: Dinesh Adiga; Kiran Khatake Cc: Jaywant Jamdade; 'RSS'; 'Anand Shah'; 'Rajdeep Valve'

Subject: RE: Malfunctioning of 2 inch Butterfly valve of UF System, in CED Line Improvement project

Dear Sir,

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Further with reference to below mail, L&T Service Engg. Mr. Sriram B plan his visit to Tata Motors – Jamshedpur on

tomorrow (01/04/2016).

Request you to kindly send contact details of concerned persons (Plustech & Tata Motors)

Mr. Sririam B. – L&T Service Engg.

Contact No. – 09051998383

Mail id - [email protected]

Complaint no. – TM00002192

Waiting for your reply............

Thanks and Regards,

Anil Y. Kankal

Mob. : +91 9881090334

Rajdeep - Pune Ph. : 020-24393753 / Web.: www.rajdeepindia.com ----------------------------------------------------------------------------


Sent: 17 March 2016 11:32

To: 'Dinesh Adiga'; 'Kiran Khatake' Cc: 'Jaywant Jamdade'; 'RSS'; 'Anand Shah'; 'Rajdeep Valve'


Dear Sir,

We thank you for the kind courtesy extended to us during our visit at your office on Monday 14/03/2016.

Further with reference to our discussion, please find our action plan to resolve the above said complaint.

1st

– We have arranged free replacement for Butterfly Valves, Size – 2” & 8”, Qty. – 01 No. each with square

stem so that actuator will be fitted directly on valve(without bracket & coupler).

We will also provide the detail procedure for mounting of actuator on valve along with images for necessary

fitting at site.

2nd

– We have register this complaint in L&T SAP, once we get the feedback from our principal for availability

of service person then we will inform you accordingly.

Request you to kindly provide the dispatch details to send replacement of Butterfly Valves, Size – 2” & 8”, Qty. – 01

No. each. After replacement kindly arrange to send faulty valves at our end & then we will send it back to L&T R&D

Dept. for detail analysis. So that we will came to know the exact reason of failure to avoid the same in future also.

Waiting for your reply to proceed further.

Thanks and Regards,

Anil Y. Kankal

Mob. : +91 9881090334


From: Kiran Khatake [mailto:[email protected]]

Sent: 10 March 2016 10:01

To: 'Anil Kankal' Cc: Dinesh Adiga; Jaywant Jamdade; 'RSS'; 'Anand Shah'; 'Rajdeep Valve'


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Dear Sir,

We don’t have any images.

please attend the problem and solve immediately

Thanks &regards

Kiran Patil


Sent: 10 March 2016 09:31

To: Kiran Khatake Cc: Dinesh Adiga; Jaywant Jamdade; 'RSS'; 'Anand Shah'; 'Rajdeep Valve'


Dear Sir,

Kindly share images of failure valves.

CC – RSS – Please act faast.

Thanks and Regards,

Anil Y. Kankal

Mob. : +91 9881090334



Sent: 09 March 2016 16:03 To: 'Anil Kankal'

Cc: Dinesh Adiga; Jaywant Jamdade; 'RSS'; 'Anand Shah'; 'Rajdeep Valve' Subject: RE: Malfunctioning of 2 inch Butterfly valve of UF System, in CED Line Improvement project

Dear Sir,

End user don’t have so much time for reply so please confirm your action plan on today itself.

Thanks & regards

Kiran Patil


Sent: 09 March 2016 15:54

To: Kiran Khatake Cc: Dinesh Adiga; Jaywant Jamdade; 'RSS'; 'Anand Shah'; 'Rajdeep Valve'


Dear Sir,

Regret for the inconvenience cause!!!!

Further with reference to your below mail, we will register your below complaint of failure of ON-OFF Butterfly

Valves.

We will revert back with our action plan as soon as we get reply from our principal. Till then please bear with us.

Thanks and Regards,

9

Anil Y. Kankal

Mob. : +91 9881090334



Sent: 09 March 2016 11:25

To: Anil; [email protected] Cc: Dinesh Adiga; Jaywant Jamdade


Dear Sir,

There was another malfunctioning observed in the 2 inch Butterfly valve, ( Tag No: 203VA 2003 ) fitted in

the circulation pipeline of UF spray, which resulted in overflow of Paint from the CED tank .The valve is

presently not functioning.

Already, 2 valves have malfunctioned within the span of 10-11 Months. This has raised doubts for these L

& T make valves fitted in the system, which may fail in future in similar fashion.

Plustech PO No - POMB0481A01 Dated - 28/01/2015

This is a very serious concern which needs your immediate attention & the way forward.

Please revert back with the action plan for replacement of these 2 valves.

Thanks & regards

Kiran Patil


Sent: 07 March 2016 17:18

To: Dinesh Adiga Cc: [email protected]; [email protected]; [email protected];

[email protected]; [email protected]; [email protected]; Jayshankar Mishra

Subject: Malfunctioning of 2 inch Butterfly valve of UF System, in CED Line Improvement project

Dear Sir,

As discussed, there was another malfunctioning observed today in the 2 inch Butterfly valve, ( Tag No:

203VA 2003 ) fitted in the circulation pipeline of UF spray, which resulted in overflow of Paint from the

CED tank .The valve is presently not functioning.

Already, 2 valves have malfunctioned within the span of 10-11 Months. This has raised doubts for these L

& T make valves fitted in the system, which may fail in future in similar fashion.

This is a very serious concern which needs your immediate attention & the way forward.

Please revert back with the action plan for replacement of these 2 valves.

Regards,

Deepein Ratra

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From: DEEPEIN RATRA [ CENT. PLANNING , Jamshedpur Works ]

Sent: Thursday, January 21, 2016 6:38 PM

To: Dinesh Adiga <[email protected]> ([email protected])

Cc: PRADEEP GUPTA [ CAB & COWL FACT , Jamshedpur Works ]; DEEPAK SINHA [ CAB & COWL FACT , Jamshedpur

Works ]; ARCHIT KUMAR [ CENT. PLANNING , Jamshedpur Works ]; ASHOK BAREJA [ CENT. PLANNING , Jamshedpur

Works ]; SUMAN CHATTERJEE [ CAB & COWL FACT , Jamshedpur Works ]; RANDHIR PRASAD [ CAB & COWL FACT ,

Jamshedpur Works ]; ROHAN UKIL [ CAB & COWL FACT , Jamshedpur Works ]; PRANAY PRASAD [ CAB & COWL FACT

, Jamshedpur Works ]; RATHINDRA BASU [ CAB & COWL FACT , Jamshedpur Works ]; GOUTAM BAG [ CAB & COWL

FACT , Jamshedpur Works ]; Jaywant Jamdade ([email protected]); Jayshankar Mishra

Subject: RE: Yesterday one hour prodution loss due to UF spray not running

Dear Sir,

This is to bring into your notice that one of the Butterfly valve installed in UF Spray system has malfunctioned

yesterday. The below mail from maintenance is self-explanatory.

Request you to confirm the reason for its malfunctioning, in such a short span of time. Since, this is under the

warranty period, please arrange to send a spare valve at the earliest.

Regards,

Deepein Ratra

From: GOUTAM BAG [ CAB & COWL FACT , Jamshedpur Works ]

Sent: Thursday, January 21, 2016 4:05 PM

To: DEEPEIN RATRA [ CENT. PLANNING , Jamshedpur Works ]


Works ]; ARCHIT KUMAR [ CENT. PLANNING , Jamshedpur Works ]; ASHOK BAREJA [ CENT. PLANNING , Jamshedpur

Works ]; SUMAN CHATTERJEE [ CAB & COWL FACT , Jamshedpur Works ]; RANDHIR PRASAD [ CAB & COWL FACT ,

Jamshedpur Works ]; ROHAN UKIL [ CAB & COWL FACT , Jamshedpur Works ]; PRANAY PRASAD [ CAB & COWL FACT

, Jamshedpur Works ]; RAKESH SHARAN [ CAB & COWL FACT , Jamshedpur Works ]; RATHINDRA BASU [ CAB & COWL

FACT , Jamshedpur Works ]

Subject: RE: Yesterday one hour prodution loss due to UF spray not running

Attached pdf.

From: GOUTAM BAG [ CAB & COWL FACT , Jamshedpur Works ]

Sent: Thursday, January 21, 2016 4:00 PM To: DEEPEIN RATRA [ CENT. PLANNING , Jamshedpur Works ]


Works ]; ARCHIT KUMAR [ CENT. PLANNING , Jamshedpur Works ]; ASHOK BAREJA [ CENT. PLANNING , Jamshedpur Works ]; SUMAN CHATTERJEE [ CAB & COWL FACT , Jamshedpur Works ]; RANDHIR PRASAD [ CAB &

COWL FACT , Jamshedpur Works ]; ROHAN UKIL [ CAB & COWL FACT , Jamshedpur Works ]; PRANAY PRASAD [ CAB & COWL FACT , Jamshedpur Works ]; RAKESH SHARAN [ CAB & COWL FACT , Jamshedpur Works ]; RATHINDRA

BASU [ CAB & COWL FACT , Jamshedpur Works ]

Subject: Yesterday one hour prodution loss due to UF spray not running

Dear Deepein,

Yesterday there is a one hour production loss as UF 1&2 spray were not functioning (Spraying was not happening).

We found that the pneumatic operated butterfly valve (200mm Dia.) present in the delivery line is not functionally

operating as the valve liver and the butterfly flap are disconnected as a result flap is not rotating when liver is

operated. We have attached a pdf for your better understanding.

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In this regard, we would like to bring your notice that within a short span of installation of setup these types of

failure shouldn’t take place. Please communicate the issue to the supply end and take necessary action so that these

types of failures shouldn’t repeat again.

Regards, Goutam Bag CPS- Maintenance

Cab & Cowl Factory Ph : 0657669 4790 , M: 9263639948

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Plustech Systems & Solutions Pvt Ltd, Pune, India

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