WORKING INSTRUCTION

BMI-WI-5711-14 Ball Valve 2in ANSI Class 900

Manufacturing Process
Revision No. : 0
Effective Date: August 27, 2015

Prepared By Reviewed By Approved by

Signature
Name Abdurrahman Maricel L. Lobis Lee Ka King
Designation Production Manager Operations Manager Managing Director
Date 12.08.2015 20.08.2015 25.08.2015
 Ball Valve 2in ANSI Class 900
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Manufacturing Process
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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 2in ANSI Class rating 900.

2.0 Scope

This procedure covers the inspection, machining, assembly, testing of Ball Valve 2in
ANSI Class 900. 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: A105+3 mill ENP
Size: 2” Seat Material: PEEK
Rating: 900# Packing & Seal Material: Graphite / Viton
Connection: Flange RF Temperature Rating: 320 to 1900 F
Style: Bolted Body Operator: Lever Operated
Seating Arrangement: Trunnion Additional Design Features:
Body Material: ASTM A105 Cavity Relief, Fire safe Design, Anti-Static,
Replaceable ball and seat
Ball Material: ASTM A105 + 3 mill ENP Stainless Steel nameplate

4.0 Responsibility

4.1 Engineering Team

 Prepares the bill of material and drawing structure logic.

4.2 Production Manager

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

4.3 Quality Manager

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

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Manufacturing Process
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4.4 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.

4.5 Machine Operators

 Operates the machines as per approved engineering drawing.

5.0 Material Receive

5.1 Receiving of Raw Material

Logistic coordinator checks the materials received against the supplier’s packing
slip and against a copy of the BMI’s 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.

5.2 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.

6.0 Fabrication Process

6.1 Cutting Process

With approved drawing released by Engineering, production manager gives the

dimension and length of the raw material that is needed.
Upon received the required length and dimension the operator will cut the raw
material accordingly and will be checked and verified by QC Inspector. Refer to
BMI-WI-5711-01 Cutting Machine Operation for details.

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6.2 Machining – Lathe Process

6.2.1 Machine operator shall Inspect equipment before use, for damage parts and
cords.
6.2.2 Prepare all lathe chisel and the measuring instrument to be used.
6.2.3 Check whether the material re-entry in the machining tolerance for or not and
use chuck 4.
6.2.4 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

6.2.5 Process (Body and Bonnet)

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

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

6.2.5.2.1 Body Process

 Grooving surface for gasket as per engineering
drawing.
6.2.5.2.2 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.
6.2.5.3 For class 300, 600 and so on, do facing the rear flange except class
150
6.2.5.4 Finish process
 Materials / components are declared fit to be
submitted or proceed to the next process

6.2.6 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

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Manufacturing Process
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6.2.7 Process 2 :
6.2.7.1 Facing surface of the body and bonnet raw material, appropriate
dimensions in the drawing

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

6.2.7.2.1 Body Process

 Grooving surface for gasket as per engineering
drawing.
6.2.7.2.2 Bonnet Process
 Facing outer and grooving for o- ring housing as per
engineering drawing.

6.2.7.3 Finish process.

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

6.3 Drilling, Milling & Tapping

6.3.1 Machine operator shall Inspect equipment before use, for damage parts and
cords.
6.3.2 Preparation
 Prepare drill and measuring devices to be used
 Use vice clamping for holding the body and bonnet.

6.3.3 Setting 1 :
6.3.3.1 Place the body and bonnet in vertical position for vice clamping to
hold.
6.3.3.2 Set the center of the diameter of the body and bonnet using
centrofix.
6.3.4 Process
6.3.4.1 Create the program of CNC milling for drill, milling and tapping
for the body and bonnet. Follow the dimensions as per engineering
drawing.

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Manufacturing Process
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6.3.5 Finish Process.

 Materials / components are declared fit to be submitted or proceed to the
next process

6.3.6 Same setting as 6.3.3 and process as 6.3.4.

6.3.7 Setting 3: Setting-up trunnion

6.3.7.1 Place the valve body in horizontal position for vice clamping to
hold the body.
6.3.7.2 Set the center of the body using centrofix.
6.3.8 Repeat process 6.3.4.
6.3.9 Finish Process.
6.3.10 Switch off the machine and reset all guards to a fully closed position.
6.3.11 Place all tools used back where they belong.
6.3.12 Leave the machine in safe, clean and tidy state.

7.0 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

8.0 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 valve’s 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.

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

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Manufacturing Process
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8.2 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.
8.3 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.
8.4 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
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.
8.5 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.
8.6 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.
8.7 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.
8.8 Place the cut ring into the upper stem and continuously into the top valve body.
8.9 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.
8.10 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.
8.11 Use the bolt and nut to tighten the operator and gland flange.
8.12Screw the sealant fittings and the drain plug into their corresponding location in
the valve bodies and tighten it.
8.13Make 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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Manufacturing Process
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9.0 Inspection and Test

9.1 Dimensional Inspection

Dimensions shall be inspected in accordance with the drawings and specified values.
Face to face tolerance for Ball valve 2”-900# is ±2mm.

9.2 Visual Inspection

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

9.2.2 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

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 900 Time Duration

A105 3356 psi 2 mins

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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 900 Time Duration

2in 2489 psi 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.

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.

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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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Manufacturing Process
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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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Manufacturing Process
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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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