18 07 Quality

Quality and
Documentation
3
2
Assembly Check
Machining check
Income Check
LESER Quality and Documentation | LESER GmbH & Co. KG | 30.03.2009 | Rev. 00
Objectives
Objectives
Quality Process
Income Check
Quality Process
Machining Check
Quality Process
Assembly Check
Objectives of this Presentation

Knowledge to Learn
This presentation will familiarize you with:
Operative quality management at the site in Hohenwestedt
LESER documentations
LESER Documentation
Summary
2 / 34
Objectives
Quality
Process
Quality Process
Income
Check
Income Check
Quality Process
Machining Check
Quality Process
Income Check
Supplier
1. Income Check
2. Machining Check
3. Assembly Check
Customer
Quality Process
Assembly Check
LESER Documentation
Summary
Assembly Check
Machining Check
Income
Check
Income Check
3 / 34
Objectives
Quality
Process
Quality Process
Income
Check
Income Check
Quality Process
1.
2.
3.
Income Check
Quality Process
Machining Check
Quality Process
Assembly Check
LESER Documentation
Summary
Check of documents
Dimension check
Ultrasonic test
Spectral analysis
Magnetic particle test
Liquid penetrant test
4 / 34
Objectives
Quality
Process
Quality Process
Income
Check
Income Check
Income Check
1.
2.
3.
Document Check
Quality Process
Machining Check
Quality Process
Assembly Check
LESER Documentation
Document Check
Purpose
To identify if ordered material

corresponds to supplied
material
To check if all required

inspections are certified
Summary
5 / 34
Objectives
Quality
Process
Quality Process
Income
Check
Income Check
Income Check
1.
2.
3.
Dimension Check
Quality Process
Machining Check
Quality Process
Assembly Check
LESER Documentation
Dimension Check
Purpose
Dimensions are measured by

different measurement
instrumentation
Form and position tolerances

are checked by means of a 3D
coordinate measuring machine
Measured dimensions are

transferred automatically into
the SAP system where they
are recorded
Summary
6 / 34
Objectives
Quality
Process
Quality Process
Income
Check
Income Check
Income Check
1.
2.
3.
Material Check by Means of

Spectral Analysis
Quality Process
Machining Check
Quality Process
Assembly Check
LESER Documentation
Summary
Material check by means

of spectral analysis
Purpose
To indicate the chemical

composition
The following elements are

checked: C, Si, Mn, P, S, Cr,
Mo, Ni, Cu, Nb, Ti, V
7 / 34
Objectives
Quality
Process
Quality Process
Income
Check
Income Check
Income Check
1.
2.
3.
Ultrasonic Check
Quality Process
Machining Check
Quality Process
Assembly Check
LESER Documentation
Summary
Ultrasonic Check
Purpose
To indicate volume defects

and cracks in castings
8 / 34
Objectives
Quality
Process
Quality Process
Income
Check
Income Check
Income Check
1.
2.
3.
Magnetic Particle Testing
Quality Process
Machining Check
Quality Process
Assembly Check
LESER Documentation
Magnetic Particle Check
Purpose
To indicate cracks on ferritic

materials close to the surface
Use of ultra violet light makes

the cracks visible
Summary
9 / 34
Objectives
Quality
Process
Quality Process
Income
Check
Income Check
Income Check
1.
2.
3.
Spring Check
Quality Process
Machining Check
Quality Process
Assembly Check
Spring Check
Purpose
LESER Documentation
To indicate the spring rate
Summary
Check of the minimum spring

deflection
To check the spring length
Check of the spring

dimensions
10 / 34
Objectives
Quality Process
Income Check
Quality Process
Quality
Process
Machining Check
Machining
Check
Quality Process
Machining Check
Supplier
1. Income Check
2. Machining Check
3. Assembly Check
Customer
Quality Process
Assembly Check
LESER Documentation
Summary
Assembly Check
Machining Check
Machining
Check
Income Check
11 / 34
Objectives
Quality Process
Income Check
Machining Check
1.
2.
3.
Hydrostatic Test of the Valve Shell
Quality Process
Quality
Process
Machining Check
Machining
Check
Quality Process
Assembly Check
LESER Documentation
Summary
Hydrostatic Test
Purpose
To check the body strength of

the pressure bearing
components of the valve shell
at 1.5 x nominal pressure
12 / 34
Objectives
Quality Process
Income Check
Machining Check
1.
2.
3.
Surface Finish Test
Quality Process
Quality
Process
Machining Check
Machining
Check
Quality Process
Assembly Check
LESER Documentation
Surface Finish Test
Purpose
Measuring and recording

of the surface quality
Mainly for Clean Service

safety valves
Summary
13 / 34
Objectives
Quality Process
Income Check
Machining Check
1.
2.
3.
Dimension Check in
the Production Process
Quality Process
Quality
Process
Machining Check
Machining
Check
Quality Process
Assembly Check
LESER Documentation
Dimension Check in the Production

Process
Purpose
Measuring and recording of all

relevant measures
Values are directly entered into

SAP
Summary
14 / 34
Objectives
Quality Process
Income Check
Quality Process
Machining Check
Quality Process
Assembly Check
Supplier
1. Income Check
2. Machining Check
3. Assembly Check
Customer
Quality Process
Quality
Process
Assembly Check
Assembly
Check
LESER Documentation
Summary
Assembly
Check
Assembly Check
Machining Check
Income Check
15 / 34
Objectives
Quality Process
Income Check
Assembly Check
1.
2.
3.
Set Pressure Test
Quality Process
Machining Check
Quality Process
Quality
Process
Assembly Check
Assembly
Check
LESER Documentation
Summary
Set Pressure Test
Purpose
To adjust the safety valve

to the specified set pressure
16 / 34
Objectives
Quality Process
Income Check
Assembly Check
1.
2.
3.
Seat Tightness Test
Quality Process
Machining Check
Quality Process
Quality
Process
Assembly Check
Assembly
Check
LESER Documentation
Summary
Kellog Test
Purpose
Check of the seat tightness

with air at 90% of the set
pressure
17 / 34
Objectives
Quality Process
Income Check
Assembly Check
1.
2.
3.
Body Tightness Test
Quality Process
Machining Check
Quality Process
Quality
Process
Assembly Check
Assembly
Check
LESER Documentation
Summary
Body Tightness Test
Purpose
To indicate the tightness

of the entire valve against
atmosphere
18 / 34
Objectives
Quality Process
Income Check
Assembly Check
1.
2.
3.
Helium Leakage Test
Quality Process
Machining Check
Quality Process
Quality
Process
Assembly Check
Assembly
Check
LESER Documentation
Summary
Helium Leakage Test
Purpose
To indicate the tightness of the

complete valve against
atmosphere
19 / 34
Objectives
Quality Process
Income Check
Assembly Check
1.
2.
3.
Retraceability
Quality Process
Machining Check
Quality Process
Quality
Process
Assembly Check
Assembly
Check
LESER Documentation
Allocation of Charge Numbers of

Components to the Safety Valve
Purpose
Allocation of individual
material certificates to the
corresponding valve
Standard for bodies / inlet,

nozzle and spring. Additional
components on request.
Summary
20 / 34
Objectives
Quality Process
Income Check
Assembly Check
1.
2.
3.
Final Inspection
Quality Process
Machining Check
Quality Process
Quality
Process
Assembly Check
Assembly
Check
LESER Documentation
Final Inspection
Purpose
To check that the valve is built

according to all customer
specifications
Inspection content is defined

by a SAP based inspection
plan
Summary
21 / 34
Objectives
Quality Process
Income Check
Quality Process
Machining Check
Documentation
Certificates Overview
LESER offers 3.1 as well as 3.2 certificates which are defined as follows:
Quality Process
Assembly Check
LESER Documentation
Documentation
Summary
Test report 2.2
Inspection Certificate 3.1
Inspection Certificate 3.2
Document in which the manufacturer declares that the

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

the products supplied are in
compliance with the requirements of
the order and in which he supplies
test results.
Document prepared by both

the manufacturers authorized
inspection representative,
independent of the manufacturing department and either
the purchasers authorized
inspection representative or the
inspector designated by the
official regulations and in which
they declare that the products
supplied are in compliance with
the requirements of the order
and in which test results are
supplied.
Uncommon at LESER
The test unit and the tests to be

carried out are defined by the
product specification, the official
regulation and corresponding rules
and/or the order.
The document is validated by the
manufacturers authorized
inspection representative,
independent of the manufacturing
department.
High cost
The majority of the certificates

issued by LESER are Inspection
Certificates 3.1.
22 / 34
Objectives
Quality Process
Income Check
Documentation
Certificates Overview
Quality Process
Machining Check
Quality Process
Assembly Check
LESER Documentation
Documentation
LESER CGA
(3.1)
Additional
3.1
certificate for
standard test
Material test
certificate
(usually 3.1)
3.2
certificate for
standard test
3.1
certificate for
specific test
3.2
certificate for
specific test
Summary
Standard tests (e.g. hydrostatic test at 1.5x set pressure)
Customer-specific tests (e.g.

hydrostatic test at customerspecific set pressure)
LESER is able to fulfil all customer requirements regarding tests and

documentation
The standard tests certified on the CGA already cover a large chunk of
customer requirements. If possible, they should be used instead of
additional tests to save time and money for the customer.
23 / 34
Objectives
Quality Process
Income Check
Documentation
Certificate for Global Application (CGA)
Quality Process
Machining Check
Quality Process
Assembly Check
LESER Documentation
Documentation
Summary
LESER CGA
Purpose
Document that identifies all

tests that were done at the
valve incl.
Inspection certificate
3.1 acc. to EN 10204
Declaration of conformity
acc. to DGRL and ASME
(UV1)
24 / 34
Objectives
Quality Process
Income Check
Quality Process
Machining Check
Documentation
The LESER CGA in Detail

Type of test certificate (3.1)
Quality Process
Assembly Check
LESER Documentation
Documentation
Relation to purchase order
Summary
Test object
Declaration of conformity
25 / 34
Objectives
Quality Process
Income Check
Documentation
The LESER CGA in Detail
Quality Process
Machining Check
Quality Process
Assembly Check
LESER Documentation
Documentation
Explanation: Reference to
external standards versus internal
LESER standard
Summary
Materials used for certain

components
Test results for standard tests
Result and medium for pressure
setting
26 / 34
Objectives
Quality Process
Income Check
Documentation
Important tests are carried out at LESER as standard practice and

documented on the CGA.
Quality Process
Machining Check
Quality Process
Assembly Check
Tests
LESER Documentation
Documentation
Summary
Directive
DIN EN
Cold differential test pressure (CDTP)
LESER
Standard
ASME Sec. VIII

UG 136(d)(4)
LGS 0202
Seat tightness
EN 12266 P12
UG 136(d)(5)
LGS 0201
Back seat tightness

(Outward tightness)
EN 12266 P21
UG 136(d)(3)
LGS 0201
Operability
EN 12266 F20
UG 136(d)(5)
LGS 0217
Back seat tightness

(Outward tightness)
EN 12266 P21
UG 136(d)(3)
LGS 0201
Shell tightness test
EN 12266 P11
Hydrostatic testing
EN 12266 P10
LGS 0201
UG 136(d)(2)
Non-destructive testing (e.g. magnetic

particle testing or dye penetrant testing)
LGS 0203
LGS 0205
Material identification (PMI)

Visual inspection of marking
LGS 0209
LGS 0207
UG 77
LGS 0218
27 / 34
Objectives
Quality Process
Income Check
Quality Process
Machining Check
Quality Process
Assembly Check
LESER Documentation
Documentation
Summary
Documentation
Additional 3.1 test certificates for standard tests

On customer request LESER issues an additional inspection certificate 3.1 for each test that is certified on the
LESER CGA. Recommendation: Check whether an additional certificate is needed because important tests
are already certified on the CGA.
Tests
Option Code
Set pressure
Inspection certificate 3.1 acc. to DIN EN 10204:

Testing of cold differential test pressure with air
N05
Component strength

Hydrostatic testing 1,5 x PN
M68

Seat tightness test with air, bubble test
Standard requirement
M66

Seat tightness test with air, test fluid
M22
Pressure bearing shell

Shell tightness test
M18
Flange safety valves

Back seat tightness test with test fluid
M28
Compact Performance safety valves

Back seat tightness test, dipping procedure
M78
Test of the valve design
Pressure-related assessment and safety related design review

Design review
M85
Volume test at the body

Ultrasonic test
M56
Tightness
Seat tightness
Back seat tightness test

(Outward tightness)
28 / 34
Objectives
Quality Process
Income Check
Quality Process
Machining Check
Documentation
Additional 3.1 test certificates for customer-specific tests

On customer request LESER conducts customer-specific tests and inspections (e.g. hydrostatic test with customer-specific
test duration and test pressure). The most common of these tests can be ordered via Option Code and come with a 3.1
certificate. Other customer-specific tests are available on request
Quality Process
Assembly Check
LESER Documentation
Documentation
Tests
Body strength
Tightness
Summary
Tightness:
Helium leakage test
Hydrostatic testing acc. to customer specification

incl. inspection certificate 3.1 acc. to DIN EN 10204
Seat tightness test with air, bubble test High tightness
Back seat tightness test with helium
N64
Seat tightness test with helium, overpressure procedure

N62
Seat tightness test with helium, leak detection in vacuum

M86
Test if free of oil and grease

Test for paint wetting impairment substances
Surface crack test
Substance test
Surface crack test
Option Code
M01
J86
J85
J74
N52 N54
Surface finish test for

components acc. to customer
specification
Surface finish test

Components are specified by customer
N04
Component test
Delivery specification acc. to NACE

incl. inspection certificate 3.1 acc. to DIN EN 10204:
Hardness test acc. to NACE
Components: body, seat / nozzle and disc
N78
Material identification (PMI)

Radiographic test
Positive material identification

Radiographic test acc. to gem. LESER film layout
N55 N57
M80 S01
29 / 34
Objectives
Quality Process
Income Check
Quality Process
Machining Check
Quality Process
Assembly Check
LESER Documentation
Documentation
Summary
Documentation
Material test certificates
Can be ordered via Option Code for most components without longer delivery time.
Are usually 3.1 certificates issued by material supplier.
Material test certificate Compact Performance
Option Code
Inlet body
DIN EN 10204-3.1
H01
Outlet body
DIN EN 10204-3.1
L34
Inlet flange
DIN EN 10204-3.1
L22
Body angle type
DIN EN 10204-3.1
H01
Type 5267 body angle type
DIN EN 10204-3.2
H09
Type 4587 body angle type
DIN EN 10204-3.2
H09
Type 447 outlet body
DIN EN 10204-3.1
L34
Body / Flange bow
DIN EN 10204-3.1
Y41
Stud
DIN EN 10204-3.1
N07
Nuts
DIN EN 10204-3.1
N08
DIN EN 10204-3.1
DIN EN 10204-3.1
DIN EN 10204-3.1
DIN EN 10204-3.1
DIN EN 10204-3.1
DIN EN 10204-3.1
DIN EN 10204-3.1
L30
L31
L59
L23
N07
N08
L60
Material test certificate flange valves
Material test certificate change-over valves
Material test certificate other components

Bonnet
Cap / Lever cover
Seat / Nozzle
Disc
Stud
Nuts
Spring
30 / 34
Objectives
Quality Process
Income Check
Quality Process
Machining Check
Quality Process
Assembly Check
LESER Documentation
Documentation
Summary
Documentation
3.2 test certificates most common: TUEV certificate for valve setting
Set pressure is already certified
on CGA as 3.1
If 3.2 certificate is required,
LESER can issue a TUEV
certificate. The process for this is
very easy as the TUEV
representative is at LESER every
day.
31 / 34
Objectives
Quality Process
Income Check
Documentation
Which Certificates are available after shipment?
Quality Process
Machining Check
Quality Process
Assembly Check
LESER Documentation
Documentation
Different cases
Option Code
1) General
All ordered Certificates!
2) Certificates not ordered, but serial

number is available.
LESER CGA
Material test report body
(Option Code H01)
3) Certificates not ordered, but code

number of single part is available.
Material test certificates:

disc
bonnet
cap
lifting device
studs and nuts
seat / nozzle
Summary
32 / 34
Objectives
Quality Process
Income Check
Quality Process
Machining Check
Documentation
Which Certificates are available?

Certificates can be retrieved at www.leser.com/en/services/certificates.html!
Quality Process
Assembly Check
LESER Documentation
Documentation
Summary
33 / 34
Objectives
Quality Process
Income Check
Quality Process
Machining Check
Quality at LESER
Summary
In total, a LESER safety valve

passes numerous standard
tests before shipment.
The tests are reliably and

comprehensibly recorded in
SAP.
The standard tests are certified

on the CGA.
Additional certificates can

easily be ordered via Option
Code.
Ordered certificates can be

downloaded at www.leser.com.
Quality Process
Assembly Check
LESER Documentation
Summary
Summary
34 / 34

18 07 Quality

Diunggah oleh

Informasi Dokumen

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

18 07 Quality

Diunggah oleh

Hak Cipta:

Format Tersedia

Quality and

Objectives of this Presentation

This presentation will familiarize you with:

Operative quality management at the site in Hohenwestedt

Magnetic particle test

Liquid penetrant test

To identify if ordered material

To check if all required

Dimensions are measured by

Form and position tolerances

Measured dimensions are

Material Check by Means of

Material check by means

To indicate the chemical

The following elements are

To indicate volume defects

Magnetic Particle Testing

Magnetic Particle Check

To indicate cracks on ferritic

Use of ultra violet light makes

To indicate the spring rate

Check of the minimum spring

To check the spring length

Check of the spring

Hydrostatic Test of the Valve Shell

To check the body strength of

Surface Finish Test

Surface Finish Test

Measuring and recording

Mainly for Clean Service

Dimension Check in the Production

Measuring and recording of all

Values are directly entered into

Set Pressure Test

Set Pressure Test

To adjust the safety valve

Seat Tightness Test

Check of the seat tightness

Body Tightness Test

Body Tightness Test

To indicate the tightness

Helium Leakage Test

Helium Leakage Test

To indicate the tightness of the

Allocation of Charge Numbers of

Standard for bodies / inlet,

To check that the valve is built

Inspection content is defined

Test report 2.2

Inspection Certificate 3.1

Inspection Certificate 3.2

Document in which the manufacturer declares that the

Document issued by the manufacturer in which he declares that

Document prepared by both

The test unit and the tests to be

The majority of the certificates

Standard tests (e.g. hydrostatic test at 1.5x set pressure)

Customer-specific tests (e.g.

LESER is able to fulfil all customer requirements regarding tests and

Certificate for Global Application (CGA)

Document that identifies all

The LESER CGA in Detail

Relation to purchase order

The LESER CGA in Detail