ICP BALL VALVES ASSEMBLY AND MAINTENANCE PROCEDURE

REF. DOC.MMM140E Rev.1 – December 2012

Fig. 140, 141, 142 & 143

Fig. 140IMF, 141IMF, 142IMF & 143IMF

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 ICP BALL VALVES ASSEMBLY AND MAINTENANCE PROCEDURE
REF. DOC.MMM140E Rev.1 – December 2012

REVIEW CONTROL

PROCEDURE REF.DOC.MMM140E

REV. DATE CARRIED OUT BY APPROVED BY DESCRIPTION

0 16-6-2004 R. Bernal J.Tejedor General adaptation to EC Directive
1 03-12-2012 N.Berger J.Tejedor Add IMF version

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 ICP BALL VALVES ASSEMBLY AND MAINTENANCE PROCEDURE
REF. DOC.MMM140E Rev.1 – December 2012

CONTENTS

1.- APPLICABLE RANGE........................................................................................................Page 4

2.- GENERAL INFORMATION .......................................................................................... Pages 5-6

 STATEMENT.
 DESCRIPTION OF APPLICABLE EQUIPMENTS
 TECHNICAL STANDARDS
 SCOPE OF USE
 DESIGN CONDITIONS

3.- INSPECTION AT RECEPTION AND STORAGE.................................................................Page 7

4.- INSTALLATION ..............................................................................................................Pages 7-9

5.- PREVENTIVE MAINTENANCE .........................................................................................Page 10

6.- MAINTENANCE OPERATIONS ........................................................................................Page 10

 PRECAUTIONS

7.- REASONS FOR PARTS REPAIR AND REPLACEMENT ........................................ Pages 11-12
7.1 LEAKAGE THROUGH THE PACKING
7.2 LEAKAGE THROUGH THE SEATS
7.3 RE-TIGHTENING OF THE PACKING
7.4 REPLACEMENT OF THE SEATS

9.- EXPLODED VIEW OF AN ICP STANDARD VALVE & IMF VERSION............................Page 13

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 ICP BALL VALVES ASSEMBLY AND MAINTENANCE PROCEDURE
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1.- APPLICABLE RANGE

DIN / ANSI RANGE

FIGURES

140 GAS 140IMF GAS

141 NPT 141IMF NPT

142 SW 142IMF SW

143 BW 143IMF BW

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2.- GENERAL INFORMATION

2.1 STATEMENT

The ICP Ball Valves have been designed and manufactured for the use, circulation and control of
fluids in those industrial processes in which conditions are suitable for the performance levels of the
valves, according to the applied standards.
Design and manufacture are in accordance with the requirements of the European Pressure
Equipment Directive 97/23/EC complying with the affected National Rules, as well as to meet the
Machines Directive 89/392/EEC, in the case of actuated assemblies.
The suitability of the materials and the design of the type of valve in terms of their working
conditions are the responsibility of the end user of the valve.

DESCRIPTION OF THE APPLICABLE VALVES

Category I Module A (according to PED DN ≥ 65)
Category SEP (DN ≤ 50)

Body Ball Bore Press. ICP Fig. DN Connections

140
A 351 CF8M 1000 PSI 10-100 T. GAS
140IMF

141
A 351 CF8M 1000 PSI 10-100 T. NPT
141IMF
Floating Full
142
A 351 CF8M 1000 PSI 10-100 SW
142IMF

143
A 351 CF8M 1000 PSI 10-100 BW
143IMF

Applied Technical Standards

EN 19: Marking of the general purpose of the industrial valves.

(Note.- Valves DN ≤ 50 belong to the category SEP, therefore, they do not have the label
CE)

Valves design ANSI B16.34

Body design
Shell thickness
Connections
Face-to-face dimensions
Shell finishing quality
Pressure testing
ANSI B16.34
ANSI B16.34
ASME B16.11 & DIN 3239 Part 2 (Fig. 142)
ASME B16.24 & DIN 3239 Part 1 (Fig. 143)
Manufacture’s standard
MSS SP 55
DIN 3230 / BS 6755 Part 1 / ISO 5208 / NF E 29-203

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 ICP BALL VALVES ASSEMBLY AND MAINTENANCE PROCEDURE
REF. DOC.MMM140E Rev.1 – December 2012

SCOPE OF INSTALLATION ACCORDING TO THE TYPE OF FLUID

(DANGEROUS FOR THE ENVIRONMENT OR HUMAN HEALTH)

FLUIDS BELONGING TO GROUP II

Non dangerous fluids, non toxic and non inflammable.

(a dangerous fluid is a substance defined in article 2, section 2 of the EC Directive 67/548, dated the 27th of June
1967, related to the legal, standard and administrative provisions as regards to classification, package and labelling
of the dangerous substances)

DESIGN CONDITIONS

FOR DESIGNATED VALVES

1000 PSI
Unit A 351 CF8M
PN Bar 69
Design Temp. ºC -10 / 200
Design pressure Bar / N/mm² 69 / 6,9
Test Temp. Ambient
Test Pressure Bar / N/mm² 103,5 / 10,35

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3.- INSPECTION ON RECEPTION AND STORAGE

3.1 All valves will be examined on reception, to ensure that they have not suffered any damages during
transport. The supplier will immediately be informed of any damages observed.

3.2 Valves will be supplied in open position as a measure of protection and to ensure that no foreign body
can damage the ball, except the ones that incorporate a simple actuator that when air fails closes
(normally closed actuator).

3.3 WARNING!
Valves will be stored under cover and protected from the inclement weather conditions and
foreign bodies.

3.4 Valves will not be unpacked until they are to be definitely installed, except for inspection purposes. After
inspection they will be packed again.

4.- INSTALLATION

4.1 The handling and transport of the valves must be carried out with extreme precaution and using the
necessary and adequate means regarding their size and weight in order to avoid any risks to those
handling them.

4.2 WARNING!
Never use the wrench to hold the valve during handling, assembly or transport.

Check the condition of the valve firstly to detect any possible damages produced during their
handling and/or transport.

Likewise inspect the inside of the valve, as well as the inside of the pipe that connects to the
valve. It is of the utmost importance to check that there are no foreign bodies that could damage the
seats and/or the ball of the valve, as these parts are fundamental for the correct functioning of the valve.

Make sure the valve pressure can fulfill the requirement of the pipe equipment. The valves have
our marking on them with the details for the size, pressure, year of manufacture, material, CE marking,
notified body number, our logo (the size is from 1-1/4” to 4” for thread end, and 1-1/4” to 6” for flanged
end)

WARNING!
When it is known or assumed that the valve is to be installed at a collection point for waste,
such as welding slag, rust or scale, protective filters or screens must be placed temporarily or
definitively (depending on the installation) upstream before the connection with the valve.

The valve must be installed in such a way that it is accessible for the necessary periodic
inspection and maintenance required to guarantee the performance levels for which it has been
designed.

ICP Standard constructions up to –10ºC have been designed without fluid direction preference,
they are“ Bi-directional”.

The valve can be installed with the stem in any position, although it is recommended that this is
done in a vertical position with the stem facing upwards.

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Tests and inspections of the open and close are necessary to see whether the ball is in the
correct position or there is any trouble for the open/close. The material of carbon steel always comes
with rust. Please make sure the rust will not affect the connection of the pipe. Besides, deflate the pipe.
The fluid inside the pipe when at high temperature will cause inflation of the pipe and therefore stress.
Then, the value of the inflation needs to be carefully calculated, otherwise, the stress will exist in the
pipe and the valve as well. But when the fluid is at low temperature, the whole situation will be different.
Notice that if the pipe shortens, something should be done to compensate for it. Make sure all the
changes of the pipe will not affect the function of the valve.

WARNING!
Valves must not support stress from the piping. The assembly must be carried out ensuring a
correct alignment and parallelism in order to make sure that it is not subject to any unexpected stress.

Make sure when installing the valve that the flange seal that connects the valve is correctly
fitted, following the seal manufacturer’s instructions, as well as ensuring that it is compatible with the
circulating fluid in the pipe.

IMPORTANT!
Carry out a final check on the valve once the installation is done, opening and closing it to make
sure that it is working perfectly.

WARNING!
Make sure that the fluid used in the cleaning operations and the way in which this is
done is compatible with the installed valve.

Once the final cleaning operations are done previous to the starting, if filters have been installed
they can be removed or, on the other hand, if the user thinks that there can be rust or scale formations,
then filters should be left permanently.

4.3 Before installation, clean the valve with compress air or clean water to de-burr it and brush out the dirt.
Also, the pipe needs to be washed.

Proper space needs to be reserved in the valve for the handle lever, because the length of lever is
longer than that of the valve, and its turning is 90 degree.

Thread end valve installation.

Make sure the thread valve matches the pipe thread. The thread is in standard size and tolerance.
Remember that the painting, lubrication or the connection sealing grease could only be put on the male
thread rather than into the body thread. Otherwise, the grease will go into the seats or other parts.
Problems will immediately show up. Usually the use of the correct size plane spanner could reduce the
damage or slant of the valve; meanwhile, when used, the spanner needs to be near the valve of the
pipe, to reduce the possibility of the damage of the valve body.

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4.3.1 Socket weld end installation

Users could ask the manufacturer to weld a 3” pipe for valve size up to 2”. This action of welding the
short pipe will not affect the body and seats. The following process shows how the disassembling of the
body and cap, and the welding of the cap into the pipe goes.

 Cut the pipe end on the right side. The diameter should be round. Remove all burr.
 Get the de-grease medicine to clean the pipe end and the inside of the socket pipe and erase all
the oil, grease and other sorts of substance.
 Put the pipe into the socket end. The pipe end needs to touch the inside, the shoulder of the valve,
then pull it to 1/16”, or users could use the movable ring to separate it. Then, make the point of
weld.
 When heating, make sure the valve is in open position, and the valve bonnet needs to be
tightened by hand. To avoid the damage of the thread, support the valve and pipe. Then they will
not be changeable when cooling.
 The pre-heating welding temperature ranges from 400 degree F to 500 degree F.
 When the first welding finished, prior to second line welding, clean and remove the scar. If the
scar exists in heating, it will cause changes to the valve or make the valve function abnormally.
 Changes of colour after welding could be removed by steel wire.

4.3.2 The Butt weld end ball valve (for 3-pc ball valve)
Users could ask the manufacturer to weld a 3” pipe for valve size up to 2”. This action of welding the
short pipe will not affect the body and seats. The following process shows how the disassembling of the
body and cap, and the welding of the cap into the pipe goes.

 Machine the pipe end, prepare the welding, and remove all burr.
 Get the de-grease medicine to clean the pipe end and the inside of the socket pipe and clean all
the oil, grease and other substance.
 Separate the connection (as Drawing 1.2 indicates), use the fixture, let the centre be in one line,
and fix the welding position.
 When heating, make sure the valve is in open position, and the valve bonnet needs to be
tightened by hand. To avoid the damage or change of the thread, support the valve and pipe.
The they will not be changeable when cooling.
 The pre-heating welding temperature ranges from 400 degree F to 500 degree F.
 When the first welding finished, prior to second line welding, the scar needs to be cleaned and
removed. If the scar exists in heating, it will cause changes to the valve or make the valve
function abnormally.
 Changes of colour after welding could be removed by steel wire.
 After welding, non-destroy testing should be performed to prove that this welding has been done
perfectly.

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5.- PREVENTIVE MAINTENANCE

5.1 Preventive maintenance operations consist basically of periodic inspections to ensure that the valve is
working correctly.

5.2 Valves must be opened and closed at least once every 6 months and depending on the type of fluid or
application of the valve, opening and closing check plans will have to be established in shorter periods.

5.3 The user will be responsible for establishing opening and closing plans that are adequate to the working
conditions and fluids used!

5.4 WARNING!
Valves should never be left opened or closed during a long period of time.

5.5 A very high torque increase could be due to the inclusion of foreign bodies in the seats, therefore,
without forcing the handling of the valve, one should proceed to the inspection of the seats in order to
avoid damages in the ball.

5.6 It is advisable to replace the seals and the seats whenever an in-depth revision of the installation is
made.

6.- MAINTENANCE OPERATIONS

PRECAUTIONS TO BE TAKEN BEFORE DISASSEMBLY!

Make sure that the line has been closed and depressurised.
Open and close the valve several times in order to release the pressure and drain the valve cavity.

WARNING!
Wear protective clothing adequate to the circulating fluid. (Comply with the safety guidelines set
up by your company!)

In closed position remove the valve from the line and clean off any remaining fluid.

Any replacement of parts must be done using the original ICP spare parts!

The manufacturer will not be responsible for the wrong functioning of the valve if original ICP
parts are not used.

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7.- REASONS FOR PARTS REPAIR AND REPLACEMENT

7.1 LEAKAGE THROUGH THE PACKING

7.1.1 If leakage is detected through the packing (10) or (6) in IMF version, then these will have
to be tighten.
Follow the instructions of section 7.3.

7.2 LEAKAGE THROUGH THE SEATS

7.2.1 If leakage is detected through the seats (5), follow instructions of section 7.4.

7.3.- TIGHTENING OF THE PACKING

DISASSEMBLY

7.3.1 Check that there is no pressure in the installation.

7.3.2 Remove the wrench nut (7) or (16) in IMF version, the thrust washer (8) or (21) in IMF version
and the handle (6) or (15) in IMF version.

7.3.3 Tighten the gland (9) or (7) in IMF version to guarantee that there is no leak.

ASSEMBLY

Check that all spare parts are ICP original, of the same material and with the same dimensions
as the parts to be replaced.

7.3.4 Fit the handle (6) or (15) in IMF version, the thrust washer (8) or (21) in IMF version and the
wrench nut (7) or (16) in IMF version.

7.3.5 Make sure that it is in a half-open position in order to check the packing. Close and check the
seats.

7.4.- REPLACEMENT OF THE SEATS

DISASSEMBLY

7.4.1 Make sure that the installation is not under pressure.

7.4.2 Remove the wrench nut (7) or (10) in IMF version, the thrust washer (8) or (21) in IMF version
and the handle (6) or (15) in IMF version.

7.4.3 Remove the valve from the line. If the circulating fluid is harmful or inflammable, precautions
must be taken to avoid accidents.

7.4.4 Remove the bolts (12) and the nuts (13) or (14) in IMF version, bearing in mind that there may
be fluid trapped in the body cavity. Separate the tailpiece (2) from the body (1).
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7.4.5 Remove the seat (5) from the tailpiece.

7.4.6 Turn the ball (3) to the closed position and remove it from the body (1). Clean the outside
surfaces of the bore and the slot.

Check the outer surface of the ball (3), specially the area in contact with the seats (5)
and the radius of transition between the exterior surface and the bore. If the ball’s surface or the
slot are damaged replace the ball (3) for a new one.

7.4.7. Remove the seat (5) from the body (1).

7.4.8 Disassembly the gland (9) or (7) in IMF version and the packing (10) or (6) in IMF version.

7.4.9 Disassembly the stem (4). Remove the stem thrust seal (11) or (8) in IMF version.

7.4.10 Clean the inside surfaces of the body (1) and tailpiece (2), specially the area of the seats (5) and
the stem (4).

7.4.11 Clean and check the stem (4).

ASSEMBLY

Ensure that all spare parts are ICP original, of the same material and with the same
dimensions as the parts to be replaced.

7.4.12 Fit the stem thrust seal (11) or (8) in IMF version onto the stem (4).

7.4.13 Insert the stem (4) into its housing through the interior of the body (1).

7.4.14 Fit the new seat (5) to the body (1).

7.4.15 Turn the stem to the closed position so that it can be inserted in the ball’s slot. Fit the ball (3) in
closed position, making sure that there is no play between the slot and the stem (4).

7.4.16 Insert the other seat (5) into the tailpiece (2).

7.4.17 Attach the tailpiece (2) to the body (1). In some of the nominal diameters the tailpiece must be
fitted in a specific position, due to the fact that the number of body-tailpiece union studs is not
equal or a multiple of the number of flange studs. Make sure that the holes of both flanges are in
the same position in relation to the symmetrical axis of the valve.

7.4.18 Tighten the bolts (12) and the nuts (13) or (14) in IMF version, following the adequate sequence.

7.4.19 Fit the handle (6) or (15) in IMF version, the thrust washer (8) or (21) in IMF version and the
wrench nut (7) or (10) in IMF version.

7.4.20 Before reassembling the valve in the line, make sure that it is in a half-open position in order to
check the packing and the body seal and then close it and test the seal of the seats.

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9.- STANDARD ICP VALVE

ICP VALVE IMF VERSION

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Cantabria, 2. Pol. Ind. Les Salines

08830 Sant Boi de Llobregat
Barcelona (España)
Tel. (+34) 936 54 86 54
Fax (+34) 936 54 86 55
www.icp-valves.com
sales@icp-valves.com

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