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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 300.
2.0 Scope
This procedure covers the inspection, machining, assembly, testing of Ball Valve 4in 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: AISI 4140
Size: 4 Seat Material: PTFE
Rating: 300# Packing & Seal Material: Graphite / Viton
0 0
Connection: Flange RF Temperature Rating: 32 to 190 F
Style: Bolted Body Operator: Lever Operated
Seating Arrangement: Trunnion 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
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5.0 Responsibility
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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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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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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.
10.2.2 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.
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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.
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.
10 Finishing Process
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10.3 Painting
Please refer to BMI-WI-5711-01 Painting Procedure.
11 Final Inspection
12 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)
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