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MANUFACTURING PROCESS

MPS.2015.02.01 Ball Valve 6in ANSI Class 300


Revision No. : 0
Effective Date: February 26, 2015

Prepared By: Reviewed By: Approved by:


Signature
Name Abdurrahman Maricel L. Lobis Lee Ka King
Designation Production Manager Operations Manager Managing Director
Date 08.02.2015 16.02.2015 22.02.2015
Doc. ID No. REVISION
Ball Valve 6in ANSI Class 300 MPS.2015.02.01 0
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1.0 Purpose

The purpose of this procedure is to provide the manufacturing process in the production
of Ball Valve Size 6in ANSI Class rating 300.

2.0 Scope

This procedure covers the inspection, machining, assembly, testing of Ball Valve 6in ANSI
Class 300. All process of manufacturing are based on API 6D, ASME B16.34 and API 578.

3.0 Specification

PRODUCT SPECIFICATION:
Type: Ball Valve Stem Material: SS ASTM A182 GR F316
Size: 6 Seat Material: PEEK
Rating: 300 # Packing & Seal Material: Graphite/Viton
Connection: Flange RF Temperature Rating: 0 to 300DEG F
Style: Split Body Operator: Gear Operated
Seating Arrangement: Trunnion Additional Design Features:
Body Material: A351 GR CF8M End of Side Entry, Fire Safe Design and Antistatic
Ball Material: ASTM A182 GR F316 Stainless Steel nameplate

4.0 Bill of Material

No Part Drawing No. Material Qty

1 Bonnet BV6-3H-15-0202.3 A351 CF8M 1


2 Body BV6-3H-15-0202.2 A351 CF8M 1
3 Ball BV6-3H-15-0202.4 A182 F316 1
4 Trunnion BV6-3H-15-0202.9 A182 F316 1
5 Bushing BV6-3H-15-0202.12 SS316 + PTFE 1
6 Drain Valve BV6-3H-15-0202.7 A105 + Zn 1
BV6-3H-15-0202.8 A193 B8M/ 8
7 Stud/ Nut
A194 8M
8 Spring BV6-3H-15-0202.7 X750 10
9 Seat Ring BV6-3H-15-0202.11 A182 F316 2
10 Seat Insert BV6-3H-15-0202.11 PEEK 2
Grease Injection BV6-3H-15-0202.7 1
11 SS316
Valve
BV6-3H-15-0202.12 SS316 + Flexible 1
12 Body Gasket
Graphite

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13 Vent Valve BV6-3H-15-0202.7 A105 + Zn 1


14 Gland Cover BV6-3H-15-0202.6 A182 F316 1
15 Packing BV6-3H-15-0202.12 Graphite 1
16 Screw BV6-3H-15-0202.7 A193 B8M 6
17 Up Seal Ring BV6-3H-15-0202.12 A182 F316 1
18 Stem BV6-3H-15-0202.5 A182 F316 1
19 Gearbox - Assembled 1
20 O-Ring BV6-3H-15-0202.11 VITON 3
21 Plug BV6-3H-15-0202.7 SS316 1
22 Nameplate BV6-3H-15-0202.10 Stainless Steel 1

5.0 Responsibility

5.1 Engineering Team


 Prepares the bill of material and drawing structure logic.

5.2 Production Manager


 Monitors and controls the production process that is carried out by the operator

5.3 Quality Manager


 Approves finished products by confirming specifications; conducting visual and
measurement tests; returning products for re-work; confirming re-work

5.4 Quality Inspector


 Doing inspection and approved incoming materials by confirming specifications,
conducting visual and measurement test.
 Doing inspection during in-process production by confirming specification by
conducting visual and measurement tests, communicating required adjustments
to production manager.

5.5 Machine Operators


 Operates the machines as per approved engineering drawing.

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6.0 Material Receive

6.1 Receiving of Raw Material


Logistic coordinator checks the materials received against the suppliers packing
slip and against a copy of the BMIs purchase order to verify that the correct items
have been shipped. The quantity of the shipment is verified in the same manner.

Logistic coordinator inspects the general condition of the material to determine


whether any external damage was incurred during shipment. Endorsed the
materials received to QC Inspector for Material Inspection.
Refer to QSP-563-01 Verification of Purchased Product & Activities for details.

6.2 Inspection of Raw Material


QC Inspector inspects the incoming materials as endorsed by logistic coordinator
for inspection. QC Inspector examines and inspects the material according to
inspection specifications and perform test according to documented testing
methods.
Refer to BMI-WI-563-02 Raw Material Acceptance Procedure for details.

7.0 Fabrication Process

7.1 Machining Lathe Process


7.1.1 Machine operator shall Inspect equipment before use, for damage parts
and cords.
7.1.2 Prepare all lathe chisel and the measuring instrument to be used.
7.1.3 Check whether the material re-entry in the machining tolerance for or not
and use chuck 4.
7.1.4 Setting 1 :
 Post a raw material in the lathe chuck
 Setting using a dial indicator on the diameter of the raw material
 If the material is already center, material ready for machining

7.1.5 Process (Body and Bonnet)


7.1.5.1 Facing surface of the body and bonnet raw material, appropriate
dimensions in the drawing

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7.1.5.2 Facing surface of the outer and inner diameter of body and
bonnet raw material, appropriate dimensions as per the drawing
provided by Engineering Department.

7.1.5.2.1 Body Process


Grooving surface for gasket as per engineering
drawing.
7.1.5.2.2 Bonnet Process
Facing surface with a faster speed for the
manufacture of RF,if RTJ follow the drawing
regarding countour
Grooving outer and inner diameter for bonnet as
per engineering drawing.
7.1.5.3 For class 300, 600 and so on, do facing the rear flange except class
150
7.1.5.4 Finish process
Materials / components are declared fit to be submitted or
proceed to the next process

7.1.6 Setting 2 :
 Release the material,reverse and put raw material in the lathe chuck
 Setting using a dial indicator on the diameter of the raw material
 If the material is already center, material ready for machining

7.1.7 Process 2 :
7.1.7.1 Facing surface of the body and bonnet raw material, appropriate
dimensions in the drawing

7.1.7.2 Facing surface of the outer and inner diameter of body and
bonnet raw material, appropriate dimensions as per the drawing
provided by Engineering Department.

7.1.7.2.1 Body Process


Grooving surface for gasket as per engineering
drawing.

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7.1.7.2.2 Bonnet Process


Facing outer and grooving for o- ring housing as per
engineering drawing.

7.1.7.3 Finish process.


Materials / components are declared fit to be submitted or
proceed to the next process
7.1.8 Switch off the machine and reset all guards to a fully closed position.
7.1.9 Place all tools used back where they belong.
7.1.10 Leave the machine in safe, clean and tidy state.

7.2 Drilling, Milling & Tapping


7.2.1 Machine operator shall Inspect equipment before use, for damage parts and
cords.
7.2.2 Preparation
 Prepare drill and measuring devices to be used
 Use vice clamping for holding the body and bonnet.
7.2.3 Setting 1 :
7.2.3.1 Place the body and bonnet in vertical position for vice clamping to
hold.
7.2.3.2 Set the center of the diameter of the body and bonnet using
centrofix.
7.2.4 Process
7.2.4.1 Create the program of CNC milling for drill, milling and tapping for
the body and bonnet. Follow the dimensions as per engineering
drawing.
7.2.5 Finish Process.
Materials / components are declared fit to be submitted or proceed to the
next process

7.2.6 Same setting as 6.3.3 and process as 6.3.4.

7.2.7 Setting 3: Setting-up trunnion


7.2.7.1 Place the valve body in horizontal position for vice clamping to
hold the body.
7.2.7.2 Set the center of the body using centrofix.

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7.2.8 Repeat process 6.3.4.


7.2.9 Finish Process.
7.2.10 Switch off the machine and reset all guards to a fully closed position.
7.2.11 Place all tools used back where they belong.
7.2.12 Leave the machine in safe, clean and tidy state.

8 Marking
Valve body is marked as required in QSP-A5-01 Control of the Application & Removal of
API Monogram. Identification markings below are marked on the valve body:
1) Manufacturers name
2) Material
3) Rating
4) Size

9 Assembly Process

Note: Before performing the assembly work, clean the working area, ensure that there
are no iron filings, rust, welding slag, and other debris inside the valve. Keep all valve
parts and the working area clean all throughout the assembly process. The working area
must be padded with any soft material or mat. Do not allow the valve body, its
components, or any of its assembled parts to have direct contact with the ground.

Be careful with the lifting and moving of the ball valves components. Excessive
force applied to the assembly may damage or deform the valve, its related parts, and its
components which may cause the ball valve to malfunction.

9.1 Refer to the General Assembly drawing to assemble the valve.


9.2 Assemble the O-ring and spring into its corresponding location in the valve seat. Fit
this assembly inside the valve body section. Assemble the O-ring and spring into the
valve seat then fit this assembly into the body cap section. Place the remaining O-
ring and gasket inside the cap section.
9.3 Place the ball inside the valve body section. Connect the assembled body cap section
and secure it with stud and nut. Tighten the bolts with a torque as specified in Table
1.
9.4 Place the antistatic components in their position located at the lower stem trunnion
and fit them into the bottom part of the valve body. Make sure that head of the

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lower stem trunnion enters the hole underneath the ball inside the valve body. Insert
the stem bearing into the lower trunnion and into the valve body.
9.5 Place the gasket and O-ring into the lower cover then fit the lower cover into the
bottom of the valve body. Secure this into the valve body and screw bolt and screw
nut and tighten it.
9.6 Secure the key into the keyway of the upper stem and fit this into the stop of the
upper stem and fit this into the top of the valve body. Make sure that its head is
properly connected to the ball. Place the stem bearing into the upper stem and
continuously into the valve body.
9.7 Place the O-rings and back-up ring into the stem retainer. Fit the stem retainer into
the head of upper stem and continuously into the valve body.
9.8 Place the cut ring into the upper stem and continuously into the top valve body.
9.9 Insert the O-ring, back-up ring gasket and packing into the gland flange. Fit the gland
flange into the head of the upper stem and mount it on the top of the valve body.
Secure it with stud bolts and tighten.
9.10 Insert the keys into the keyway of the upper stem. Place the operator correctly
into the top of the valve stem which should come in contact with the top of the valve
body.
9.11 Use the bolt and nut to tighten the operator and gland flange.
9.12 Screw the sealant fittings and the drain plug into their corresponding location in
the valve bodies and tighten it.
9.13 Make the valve actuate once or twice by rotating the driving device to ensure
the accuracy and reliability of the valve. Finally, rotate the valve at fully open
position.

10 Inspection and Test

10.1 Dimensional Inspection

Dimensions shall be inspected in accordance with the drawings and specified


values.
Face to face tolerance for Ball valve 6-300# is 1.5mm.

10.2 Visual Inspection


10.2.1 Machined faces and all surfaces are free from flaws or unevenness on
finished surfaces.

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10.2.2 The fluid passage is finished appropriately and free from foreign debris.

10.2.3 Angles and corners the dimensions of which are not specified in the
drawings and standards are chamfered and rounded appropriately.

10.2.4 The nominal pressure, nominal diameter, and other necessary information
should be properly indicated on the body surface and label.

10.2.5 The flow direction shall be properly indicated when restricted.

10.2.6 Bore should be unobstructed when valve is in full open position.

10.3 Pressure Test

10.3.1 Shell Test

With the valve kept half open, fill the body with water and apply test pressure
shown in Table 1. Make sure that the connections are tight then use leak detector
spray on all body joins & body surfaces to ensure zero leakage and all parts are
free from leakage.
Table 1. Shell Test
Shell Material Class 300 Time Duration

CF8M 1110 psi 5 mins

10.3.2 High Pressure Valve Seat Test

With the valve closed fully, test in both directions, one direction at a time at
pressure given in Table 2. Use bubble test to ensure zero leakage.

Table 2. High Pressure Valve Seat Test


Size Class 300 Time Duration

6in 840 5 mins

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10.3.3 Low Pressure Valve Seat Test (Gas)

With the valve closed fully, test in both directions, one direction at a time at
pressure of 0.6Mpag. Use Bubble test to ensure zero leakage. An acceptance
criterion for closure test is 0 leakages.

11 Finishing Process

11.1 Name plating


Refer to QSP-A5-01 Control of Application & Removal API Monogram.

11.2 Cleaning and Anti-rust coating


The interior of the valve is to be sprayed or coated with rust preventative oil to
prevent rust and corrosion during transit and storage.

11.3 Painting
Please refer to BMI-WI-5711-01 Painting Procedure.

12 Final Inspection

12.1 Paint Check


a. The paint check shall be made after the above-mentioned tests have been
completed.
b. Check that finished coat is free from peeling, unevenness, blistering, etc.
c. Specification and color shall be in accordance with customer specifications.
Unless otherwise not specified.

12.2 Ensure that all marking and tagging are correct.

12.3 Body finish of casting/forging to be physically inspected.

13 Packing/Storage

Please refer to BMI-WI-5761-02 Preservation of API 6D Products and BMI-WI-5762-01 Packaging


Instruction.

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JOB ORDER
(Operation Manager)

SHOP ORDER
(Production/PPIC)

DESIGN&DRAWING
(Engineering Team)

Drawing NO
& BOM

YES

MATERIAL REQUISITION
(Production)
YES

NO PURCHASE REQUISITION PURSHASE ORDER


Stock
(Logistics) (Purchasing)

YES

RELEASE MATERIAL YES QC RECEIVING MATERIAL


(Logistics) verified (Logistics & QC)

NO

Machining Work
Instruction
MACHINING PROCESS
(Production)
a) Cutting b) Lathe
c) Milling d) Marking

YES

INSPECTION NO NO REJECTED
REWORK
(Quality Control) (Scrap)

NCR
(QC Inspector)
A

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YES Assembly
Procedure
ASSEMBLY
(Production)

YES

INSPECTION NO NO REJECTED
REWORK
(Quality Control) (Scrap/Rejected Area)

NCR
YES
(QC Inspector)
Hydrotest
HYDROTEST Procedure
(Production)

NO
INSPECTION REPAIR
(Quality Control) (Production) NCR
(QC Inspector)

YES Painting
Procedure
PAINTING
(Production)

NO
FINAL
REPAIR
INSPECTION
(Production) NCR
(Quality Control)
(QC Inspector)

YES
Preservation of
PRESERVATION Product Procedure
(Logistics)

STORAGE
(Ware House Area) Page 11