RUSTY COMPONENT GV

PROBLEM STETMENT:
After Dismantling the 2-1/16 FE FC DD-NL PSL3 GV, observed rust on components.
INITIAL OBSERVATIONS:
Observed Rust on Gate & Seat Body.
Rust also observed on Seat, Body seat Pocket.
Observed water in body cavity.
Greasing was insufficient.
Observed Pitting on stem.
Observed rusty patches in Flow bore in
flanged side.

VALVE HOSTORY:
These valves were tested OK & Packed after greasing approx. 1- 1/2 month ago.
These valves are reopened for the purpose of replacing the seat & gate with HF
components.
These are 2 1/16 10K FC FE GV, PU, DD-NL, PSL3, PR1.

MATERIAL USED
PART NAME

MATERIAL USED

BODY
BONNET
SEAT
SEAT BODY
REINFORCER PLATE
GATE
STEM

AISI 4130
AISI 4130
AISI 4130 NITRIDED
AISI 4130 -------410 SS or 4130 with ENP
AISI 4130
AISI 4130 NITRIDED------ 410 SS
AISI 4130 NITRIDED--------SS 410

Body, Bonnet, Reinforcer plate, are phosphated except seat body.

RUSTY NITRIDED COMPONENTS

Sr.
no. Possible Reasons

Observations

Due to unrupture style of body desing it is

difficult to Drain all the water from body
1.0 No water Drained after testing. cavity.

Remarks
Need to provide attention by assembly
supervisor to drain max. water from
body cavity.

Can we provide the drain port at body

bottom?-------------no

2.0 Insufficient nitriding layer.

Confirmed with the process & no prolem

observed with nitriding. At worst 0.003"
nitriding layer will remain as per our set
process & is sufficient as per spec.

As per process we remove only 0.0004 More material removed during 0.0005" (10-15 micron) material during
3.0 lapping after nitriding.
lapping.

Grease used not meeting the

6.0 requirement.

Hardness of water for the testing

water used for testing may be hard water & observed more, need more
no inhibiter used.
investigation from Quality on this.
-----------change better inhibiter but no
BLASOCUT 4000 as inhibiter to be used.
name suggested
to be controlled by Assembly & Quality.
Jet Lube Grease to be used by assembly
Use JetLub Grease
peoples for greasing.

Found stem, Seat & grease in

7.0 rusty condition.

Analysis to be conducted by quality.

4.0 Corrosive testing media used.

5.0 No inhibiter used..

Components used fro nitriding If this is condition, this to be avoided in

Need more investigation on this from

NITRITED GATES OBSERVED RUSTY

RUSTY SEAT ON SEALING FACE AS WELL AS BACKFACE

STEM OBSERVED RUSTY

AT SEALING AREA &
BACKSEATING FACE.

BODY BUSHING

BODY BUSHING OBSERVED RUSTY, WE HAVE NOT PROVIDED ANY COATING ON OUR DRAWING.
NEED TO PROVIDE PHOSPHATING ON THE BODY BUSHING.

WATER IN BODY CAVITY:

NO PROPER WATER DRAINING DONE AFTER

TESTING.
NOT POSSIBLE TO DRAIN COMPLETE WATER
FROM BODY CAVITY
GREASING DOSENT PUSH REMAINED WATER
THROUGH THE BODY.

WATER OBSERVED IN BODY CAVITY

NOT POSSIBLE TO DRAIN 100% WATER FROM

CAVITY.
DO WE NEED TO PROVIDE DRAIN HOLE IN
BODY?
REMAINED WATER CAN BE DRAINED DURING
GREASING, BUT IT IS NOT FULLPROOF METHOD.

RUST OBSERVED IN BODY

RUST OBSERVED IN FLOWBORE.

SEAT POCKET AREA OBSERVED RUSTY

BONNET ALSO CAPTURED RUST ON PHOSHHATED AREA

INSUFFICENT GREASING

PROBLEMS IDENTIFIED
GREASING CHECKPOINT IS NOT
SUFFICIENT.
OPERATOR MISTAKES/NEGLIGANCE
QUALITY OF GREASE USD.

POSSIBLE REASONS
DO WE NEED TO PROIDE GREASING PORT
AT BODY BOTTOM.
NEW GREASE SUGGESTED FROM
HOUSTON JET LUBE GREASE IS NOT USED
BY ASSEMBLY PEOPLES.

OBSERVED PITTING ON STEM

SOME OF THE STEMS OBSERVED PITTING & RUST.

NED TO TEST FOR CORROSION TEST.
NEED TO CONDUCT SALT BATH TEST OR IGC FOR NITRIDED STEMS/OTHER COMPONENTS.

TESTING MEDIA USED:

TESTING MEDIA USED IS WATER WITH

BLASOCUT 4000 AS INHIBITER.

TESTING MEDIA NEED TO BE CHECKED &

CHANGED ON REGULAR BASIS.
DURING TEST OF ONE OF THE WATER
HARDNESS TEST WATER USED AS INPUT
FOR TESTING OBSERVED HARD WATER.