Thanks for confirmation of the valve. Unfortunately, we are too late to install in the current shutdown (heat up already due to recommence).

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Ralf Cannon
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1 Ramachandran Sent: 28 June :49 Subject: RE: Hinge pin cover gasket for 6" 600 valve Thanks for confirmation of the valve. Unfortunately, we are too late to install in the current shutdown (heat up already due to recommence). I will ensure that it is installed at the next opportunity and feedback accordingly. From: Ramachandran [mailto:r@larsentoubro.com] Sent: Saturday, June 25, :30 PM Cc: S Venkatesh, AWB of the valve is as attached. Do let us know when you are in receipt of the valve. Also once the installation is done. Kindly do inform us of the performance. >>> On 03/06/2011 at 07:25, in message <914BC44AC CB03B50E37E425A027061C9@amsdc1-s europe.shell.com>, <.Henderson@shell.com> wrote: Good morning The shipment can be sent to the following: For attention of: Henderson (SMDS warehouse) Shell MDS (M) Sdn Bhd P.O. Box 1084, Tanjong Kidurong, Bintulu, Sarawak, Malaysia Kind regards 1

2 From: Ramachandran Sent: Wednesday, June 01, :53 PM, The valves going to be ready in another days. Could i know the consignee details and contact details at site to whom i should send the shipment. >>> On 18/05/2011 at 13:03, in message <914BC44AC CB03B50E37E425A02656DAE@amsdc1-s europe.shell.com>, <.Henderson@shell.com> wrote: Thanks for updating I ll keep in the schedule for now. From: Ramachandran [mailto:r@larsentoubro.com] Sent: Wednesday, May 18, :14 PM Dear, The castings for the body and cover and come and we intend to keep the valve ready in 2 weeks time. We may have a coordinated effort in shipment to enable the valve reach site in the required time. Will keep you updated on the valve. >>> On 18/05/2011 at 11:33, in message <914BC44AC CB03B50E37E425A02656CFC@amsdc1-s europe.shell.com>, <.Henderson@shell.com> wrote: Good afternoon Is there any update on the delivery of the check valve? I am firming the schedule for June shutdown and want to know whether to include or not. If it is not possible in June, we will push back to next shutdown period. 2

3 From: Ramachandran Sent: Wednesday, April 20, :33 PM Cc: Rahul Rudy; Ravi Chandran; S Venkatesh; Tay, Buang-Ngiak SMDS-UIA/G/MME45; Eilers, Koos GSNL- PTU/GSOE; Schmitz-Goeb, Manfred GSDE-PTU/GSED; Fernie, Martin J GSNL-PTU/GTEC; Chua, Peng-Hock SMDS-UIA/G/MME4; Nash, Robin J SMDS-UIA/G/MMT2; Felske, Sven GSNL-PTU/GTEC Dear, Regret the delay in response. We would manage to manufacture a replacement valve and supply the same onsite latest by 3rd or 4th week of June Request your understanding. >>> On 18/04/2011 at 05:53, in message <914BC44AC CB03B50E37E425A0256E80D@amsdc1- s europe.shell.com>, <.Henderson@shell.com> wrote: Good morning In response to your question on the fluid properties, see replies on the thread. Would appreciate initial estimate to timing for having the valve onsite in Malaysia. What is the probability that we meet June 15 th 2011 (our next inspection shutdown). From: Ramachandran [mailto:r@larsentoubro.com] Sent: Monday, April 11, :39 PM Cc: Rahul Rudy; Ravi Chandran; S Venkatesh; Tay, Buang-Ngiak SMDS-UIA/G/MME45; Eilers, Koos GSNL- PTU/GSOE; Schmitz-Goeb, Manfred GSDE-PTU/GSED; Fernie, Martin J GSNL-PTU/GTEC; Chua, Peng-Hock SMDS-UIA/G/MME4; Nash, Robin J SMDS-UIA/G/MMT2; Felske, Sven GSNL-PTU/GTEC Dear, We would be sending a replacement valve for this valve. We are checking with our sub vendors what best they can offer on the delivery front. We may need some more time to respond on that part. Meanwhile for all the 3 cases mentioned below could you help with the details as mentioned below which we need for internal records. 3

4 - Is the fluid steam alone or a mixture with steam[.henderson] The medium is 100% saturated steam. - temp of line steam[.henderson] - Working temperature, 280 degrees C, Design temperature, 300 degrees C. - Pressure of line steam[.henderson] Working pressure, 63 barg, Design pressure, 66 barg. I will keep you updated on the delivery in a short while. >>> On 01/04/2011 at 12:09, in message <914BC44AC CB03B50E37E425A024F41EB@amsdc1-s europe.shell.com>, <.Henderson@shell.com> wrote: Thanks for the swift response. We would be happy to trial your new design in our unit (to replace the damaged valve we currently have installed). My suggestion would be that the valve is provided free of charge. Once confidence is restored, then we can consider replacing the other valves as and when require. Do you have an estimated time for delivery? Our next scheduled maintenance stop is June From: Ramachandran [mailto:r@larsentoubro.com] Sent: Friday, April 01, :19 PM Cc: Rahul Rudy; Ravi Chandran; S Venkatesh; Tay, Buang-Ngiak SMDS-UIA/G/MME45; Eilers, Koos GSNL-PTU/GSOE; Schmitz-Goeb, Manfred GSDE-PTU/GSED; Fernie, Martin J GSNL-PTU/GTEC; Chua, Peng-Hock SMDS-UIA/G/MME4; Nash, Robin J SMDS-UIA/G/MMT2; Felske, Sven GSNL-PTU/GTEC Dear, Thanks for your feedback on the situation. We at our end also have felt the need of eliminating the hinge pin cover from the check valve especially for the high temp/steam services and low fugitive emission class requirements. We have started providing valves with internal hinge pin where the requirement of hinge pin cover is eliminated. We suppose we the problems as experienced below would be eliminated by this design. We could discuss further of the replacement of the valves with new valves. >>> On 01/04/2011 at 11:21, in message 4

5 wrote: Good afternoon Concerning the hinge pin cover flange we were unsuccessful with the attempt to lap the sealing surface with the valve on site. As a temporary get-by, we have seal welded the cover flange to the valve body in order to be able to start-up the unit again. Some general feedback to Audco. This is the 3 rd time that we have a leak through the hinge pin cover flange in under 2 years of operation. On the previous 2 occasions, we were able to isolate the check valve and replace the gasket before steam cut became an issue. Most importantly, we could do this without taking the unit out of operation. In terms of long-term reliable operation of the unit, being forced into maintenance stops because of a hinge pin cover flange is a nuisance that we wish to avoid at all costs. We need to replace the check valve that we have seal welded at the first opportunity (currently envisioned for June 2011). However, I fear that if we replace with another Audco valve that we will be in the same position again in the near future. I intend to source elsewhere unless your technical team can propose a solution that meets our reliability requirements. Attached for your information is the damage to the valve. From: Ramachandran [mailto:r@larsentoubro.com] Sent: Thursday, March 31, :29 PM Subject: Hinge pin cover gasket for 6" 600 valve, Could you update if the modification has gone well. Have you tested the valve further? Kindly advise. >>> On 25/03/2011 at 05:10, in message <914BC44AC CB03B50E37E425A024BA743@amsdc1-s europe.shell.com>, <.Henderson@shell.com> wrote: The PDF is not complete only shows a section of the actual drawing and I cannot see the section I need. Can you re-pdf correctly or just send the.dwg file. Thanks 5

6 From: Ramachandran Sent: Thursday, March 24, :31 PM Cc: S Venkatesh; Eilers, Koos GSNL-PTU/GSOE; Fernie, Martin J GSNL-PTU/GTEC; Karzel, Paul GSDE-PTU/GSED; Nash, Robin J SMDS-UIA/G/MMT2; Felske, Sven GSNL-PTU/GTEC, Per your request, Attached the drawings for your information. Kindly let me know if you need any further support. >>> On 24/03/2011 at 15:51, in message <914BC44AC CB03B50E37E425A0247ABFD@amsdc1-s europe.shell.com>, <.Henderson@shell.com> wrote: Thanks for the swift response. We will not reduce the wall thickness. First we apply an overlay weld to fill the gap in the face which has been eroded by the high pressure saturated steam. This is then followed by a lapping process to the original valve dimensions. Many thanks for forwarding the drawings to allow correct profile of the flange face. From: Ramachandran [mailto:r@larsentoubro.com] Sent: Thursday, March 24, :22 PM Cc: S Venkatesh; Eilers, Koos GSNL-PTU/GSOE; Fernie, Martin J GSNL-PTU/GTEC; Karzel, Paul GSDE-PTU/GSED; Nash, Robin J SMDS-UIA/G/MMT2; Felske, Sven GSNL-PTU/GTEC Dear, I could send you the drawings requested by you. Based on your proposal we have discussed with our plant. Since your proposal would lead to removal of material from the area, This could affect the wall thickness and the soundness of the casting. It would be better alternative to replace it with a new valve. I could check up with my sources and advise what best we can deliver this valve by once you order the valve. Looking forward to your opinion. 6

7 >>> On 24/03/2011 at 15:16, in message wrote: Hoping you can assist with some details required for repairing the check valve that you provided the cover flange / gasket for. I need a detailed drawing of the exact profile around the hinge pin gasket / cover flange area. Basically, we have almost 3mm steam cut on the sealing face and we have to overlay weld / machine back to the original profile. This is what I need you to provide confirmation on. Can you send me the detailed drawing of this section (please look at the attachments for clarification). Please treat this as urgent we will execute the overlay weld tomorrow morning and want to lap the face tomorrow afternoon. From: Ramachandran [mailto:r@larsentoubro.com] Sent: Thursday, February 10, :01 PM Cc: S Venkatesh Dear, The spares have been sent by Fedex courier vide FedEx AWB # Please confirm once you receive the same. Looking forward to hearing from you. Thanks & Regards >>> On 27/01/2011 at 10:17, in message <914BC44AC CB03B50E37E425A0227A8A4@amsdc1-s europe.shell.com>, <.Henderson@shell.com> wrote: Thanks I await your confirmation on delivery times. 7

8 From: Ramachandran Sent: Thursday, January 27, :46 PM Cc: S Venkatesh Dear, I have just ordered the spares to be sent to you and shall advise you the despatch details as soon as possible. Attached is the drawing of the valve for your reference. Thanks & Regards >>> On 21/01/2011 at 12:46, in message <914BC44AC CB03B50E37E425A022798E6@amsdc1-s europe.shell.com>, <.Henderson@shell.com> wrote: If the metal is cut due to the flashing of steam from 60 bar to atmosphere, then the metal flange face may be damaged (see attached for example of what steam cut can do under these conditions). It will therefore require lapping (grinding of material) to make the surface smooth again. Could you please send me a drawing of the check valve so I can prepare the workshop for the repair? By all means send the spares to the following address: F.A.O. Henderson (PreFurn Project) Shell MDS (M) Sdn Bhd P.O. Box 1084 Tanjong Kidurong Bintulu Sarawak Malaysia From: Ramachandran [mailto:r@larsentoubro.com] Sent: Friday, January 21, :11 PM Cc: S Venkatesh Subject: Hinge pin cover gasket for 6" 600 valve Sir, We intend to send the below items as spares. 1 Qty Hinge pin cover. 1 Qty Gasket for Hinge pin cover. 8

9 Set of 3 Stud and Nuts for Hinge pin cover With the details we have received from you, We feel that these spares would be necessary for resolution. Trust the same is in line. Kindly confirm the address and contact details to enable us to send the spares. Thanks >>> On 21/01/2011 at 12:23, in message <914BC44AC CB03B50E37E425A022798D2@amsdc1-s europe.shell.com>, <.Henderson@shell.com> wrote: Before you send can you provide some details as to what the repair entails? It is a like-for-like replacement? There may be considerable steam cut on the flange surface which could potentially require grinding before re-gasketing. This should be taken into consideration. From: Ramachandran [mailto:r@larsentoubro.com] Sent: Friday, January 21, :51 PM Cc: S Venkatesh Subject: RE: Fwd: FW: Valve data sheet request Dear, We would send you the necessary repair kit. Please advise which address to send the same. Thanks & >>> On 21/01/2011 at 08:34, in message <914BC44AC CB03B50E37E425A0223FB21@amsdc1-s europe.shell.com>, <.Henderson@shell.com> wrote: Hi Many thanks for getting back. I can confirm that the leak is through the hinge pin cover flange. We also had this same problem on an identical check valve in saturated steam service in I have no photographs available but confirm that there are two steam jets from the cover flange. 9

10 The type of flange (triangular face) appears to cause problem. Can you recommend a repair procedure (to standard flat gasket) which would be more reliable? Thanks in advance From: Ramachandran [mailto:r@larsentoubro.com] Sent: Friday, January 21, :30 AM Cc: S Venkatesh Subject: Re: Fwd: FW: Valve data sheet request Dear, We regret the delay in response. We have been unsuccessfully trying to reach you in your Malaysia numbers for a while. Need a clarification as below. 1) Is the leakage through the Hinge pin cover flange? Or the cover flange of the valve. 2) Would you be able to send a few photographs to us for us to check and advise you the suitable remedial procedures and send you the suitable spares for the same. Looking forward to your response. Should you have any queries, Feel free to contact us at the below number. R Sales Engineer Valves Business Group Larsen & Toubro Ltd No: 10, Club House Road, Anna Salai, Chennai Ph : Fax: >>> <.Henderson@shell.com> 1/19/ :10 PM >>> Dear Sir / Madam I sent the below and did not receive any response from L&T. I need to know the size of the cover flange for the attached check valve, DN150. Can you please advise? Henderson 10

11 Gasification Engineer Shell Global Solutions International BV P.O. Box 38000, 1030 BN Amsterdam, The Netherlands Tel: Fax: Internet: <outbind://34/ Currently assigned to: Shell MDS (M) Sdn Bhd P.O. Box 1084, Tanjong Kidurong, Bintulu, Sarawak, Malaysia Office: Mobiles: Established at The Hague,, Carel van Bylandtlaan 30, 2596 HR The Hague, Commercial Register, The Hague , VAT number: NL B59 From: Henderson, A GSNL-PTU/GTEC Sent: Thursday, January 13, :28 AM To: 'valves@larsentoubro.com' Cc: Nash, Robin J SMDS-UIA/G/MMT2; Felske, Sven GSNL-PTU/GTEC Subject: Valve data sheet request Dear Sir / Madam We currently have a leak on a check valve supplied by L&T. This is a Shell project, Prefurn, at SMDS in Bintulu, Malaysia. Unfortunately I cannot find details on the valve specification here on site. The information I have is as follows: Type valve: Check valve DN: 150 MESC code: I have also attached a 'print-screen' from the two year spare parts list from L&T for this project. We do carry in stock the DN150 cover gasket for this valve - perhaps this information can assist in locating the engineering drawing? Please treat this request as urgent - we have pending shut-down due to leakage and need the drawing to decide on possible rectification methods. 11

12 Henderson Gasification Engineer Shell Global Solutions International BV P.O. Box 38000, 1030 BN Amsterdam, The Netherlands Tel: Fax: Internet: <outbind://34/ Currently assigned to: Shell MDS (M) Sdn Bhd P.O. Box 1084, Tanjong Kidurong, Bintulu, Sarawak, Malaysia Office: Mobiles: Established at The Hague,, Carel van Bylandtlaan 30, 2596 HR The Hague, Commercial Register, The Hague , VAT number: NL B59 12

Rajesh S. Regards, VigneshWaran N Quality control L&T Valves. Senthil Sir, Please Find attached test certs for the Returned Valves.

Rajesh S. Regards, VigneshWaran N Quality control L&T Valves. Senthil Sir, Please Find attached test certs for the Returned Valves. From: Sent: To: Cc: Subject: Attachments: Importance: Tuesday, May 16, 2017 8:55 AM Senthil Kumar; Umesh N Kannan S; Govindharaj M; Mahalakshmi B; Mohamed Ismail S; Sgunasekaran; Vivek Anand; VAMS-FCPC;