MANUFACTURING PROCESS

MSP.2015.07.01 Ball Valve 4in ANSI Class 150

Revision No. : 0
Effective Date: 29-Jul-2015

Prepared By Reviewed By Approved by

Signature
Name Elmer Vercida Maricel L. Lobis Lee Ka King
Designation Production Engineer Operations Manager Managing Director
Date 29-Jul-2015 29-Jul-2015 29-Jul-2015
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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 4in ANSI Class rating 150.

2.0 Scope

This procedure covers the inspection, machining, assembly, testing of Ball Valve 4in ANSI
Class 150. 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: AISI 4140
Size: 4 Seat Material: PTFE
Rating: 150# Packing & Seal Material: Graphite / Viton
0 0
Connection: Flange RF Temperature Rating: 32 to 190 F
Style: Bolted Body Operator: Lever Operated
Seating Arrangement: Floating Additional Design Features:
Body Material: A216 WCB Cavity Relief, Fire safe Design, Anti-Static,
Replaceable ball and seat
Ball Material: ASTM A105N + 3 mill ENP Stainless Steel nameplate

4.0 Bill of Material

No Part Drawing No. Material Qty
1 Body BV4-1H-15-0502.2 A216 WCB 1
2 Seat Insert BV4-1H-15-0502.6 PTFE 2
3 Bonnet BV4-1H-15-0502.3 A216 WCB 1
4 Lower Gasket BV4-1H-15-0502.11 PTFE 1
5 Gland BV4-1H-15-0502.9 A216 WCB 1
6 Stem BV4-1H-15-0502.5 AISI 4140 1
7 Screw BV4-1H-15-0502.9 ASTM A193 B7 1
8 Lever BV4-1H-15-0502.8 A216 WCB 1
9 Packing BV4-1H-15-0502.11 Graphite 1
10 Positioning Plate - Cs + Zn 1
11 Body Gasket BV4-1H-15-0502.11 SS304 + Graphite 1

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12 Ball BV4-1H-15-0502.4 A105N+ENP 1

13 Nut BV4-1H-15-0502.7 ASTM A194 2H 8
14 Stud Bolts BV4-1H-15-0502.7 ASTM A193 B7 8
15 Nameplate BV4-1H-15-0502.10 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.

6.0 Receiving Inspection

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.

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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.
7.1.4 Set the raw material in the lathe chuck
7.1.5 Using a dial indicator on the diameter of the raw material find the center.
7.1.6 If the material is already center, material ready for machining.
7.1.7 Process Body
7.1.7.1 Facing surface of the body material refer to BV4-1H-15-0502.2.
7.1.7.2 Facing surface of the outer and inner diameter of body material refer
to BV4-1H-15-0502.2.
7.1.7.3 Grooving surface for body gasket refer to BV4-1H-15-0502.2.
7.1.7.4 In-process inspection of the dimension.

7.1.8 Process Bonnet

7.1.8.1 Facing surface of the bonnet material refer to BV4-1H-15-0502.3.
7.1.8.2 Facing surface of the outer and inner diameter of bonnet material
refer to BV4-1H-15-0502.3.
7.1.8.3 Grooving outer and inner diameter for bonnet refer to BV4-1H-15-
0502.3.

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7.1.9 Materials / components are declared fit to be submitted or proceed to the

next process.

7.2 Drilling, Milling & Tapping

7.2.1 Machine operator shall Inspect equipment before use, for damage parts and
cords.
7.2.2 Prepare drill and measuring devices to be used.
7.2.3 Use vice clamping for holding the body and bonnet.
7.2.4 Create the program of CNC milling for drill, milling and tapping for the body
and bonnet refer to BV4-1H-15-0502.2 Bonnet Drawing and BV4-1H-15-0502.3
Body Drawing.
7.2.5 Place the body and bonnet in vertical position for vice clamping to hold.
7.2.6 Set the center of the diameter of the body and bonnet using centrofix. Start
the process.
7.2.7 Materials / components are declared fit to be submitted or proceed to the
next process
7.2.8 Process Trunnion
7.2.8.1 Place the valve body in horizontal position for vice clamping to hold
the body.
7.2.8.2 Set the center of the body using centrofix.
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.

8.0 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
5) Serial Number (Bonnet)

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9.0 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 Place one seat into the valve body and place gasket, O-ring and another seat into
the valve body cap.
9.3 Place anti-static spring and anti-static steel ball into the stem at their
corresponding location. Insert thrust washer, bearing and O-ring onto the valve
stem and install valve stem to the body from the inside or using the largest
opening of the body. Position the stem with the lower flat head below and should
be parallel with the flow passage.
9.4 Rotate ball to the fully closed position or ball flow holes positioned sideways and
against the flow passage and place the ball into the body. Make sure that the flat
head portion of stem slides through the slotted portion of the ball and is firmly
connected.
9.5 Connect body cap to the valve body and screw bolt into the valve body through
the flange hole in the body cap. Screw nut into the other end of the bolt to
compress body cap and body tightly.
9.6 Insert packing and gland flange onto the valve stem and make sure it is properly
fitted into the body. Screw in stud to hold the packing, gland flange and valve
stem together then tighten.
9.7 Place stopper on top of the gland flange then use a special tool to splay one snap
ring and place it on the lower slot of the upper flat head of the stem to lock the
stopper in its position.
9.8 Place the hand lever onto the valve stem. Make sure that the hand lever hole is
properly inserted to the upper flat head of the valve stem. Hand lever should be

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parallel with the flow passage or the pipeline for fully open position and should
be perpendicular with the pipeline for fully closed position.
9.9 Secure hand lever position by locking it with another snap ring. Use special tool to
splay the snap ring. Insert washer and screw in stud tightly onto the valve stem.
9.10 Rotate hand lever to fully open and fully closed position and vice versa to
make sure that the ball rotates as the hand lever rotates.

10.0 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 4-150# is 1.5mm.

10.2 Visual Inspection

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

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

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

9.2.4 The nominal pressure, nominal diameter, and other necessary

information should be properly indicated on the body surface and
label.

9.2.5 The flow direction shall be properly indicated when restricted.

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

9.3 Pressure Test

9.3.1 Shell Test

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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 150 Time Duration

WCB 455psi 2 mins

9.3.2 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 150 Time Duration

4in 328psi 2 mins

9.3.3 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.

10 Finishing Process

10.1 Name plating

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

10.2 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.

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

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11 Final Inspection

11.1 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.

11.2 Ensure that all marking and tagging are correct.

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

12 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)

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