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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
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5.0 Responsibility
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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.
7.1.6 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.
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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.
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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.
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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.
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
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.
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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
11.3 Painting
Please refer to BMI-WI-5711-01 Painting Procedure.
12 Final Inspection
13 Packing/Storage
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JOB ORDER
(Operation Manager)
SHOP ORDER
(Production/PPIC)
DESIGN&DRAWING
(Engineering Team)
Drawing NO
& BOM
YES
MATERIAL REQUISITION
(Production)
YES
YES
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