Genebre 2025 Manual de usuario

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A. LAST UPDATE: 25/06/2010 UPDATE NUMBER: 1

INSTALLATION, OPERATION AND MAINTENANCE

MANUAL

3 piece Full Bore Ball Valve, Direct assembling, Threaded

ends, Butt Weld, Socket Weld and Clamp

GENEBRE Reference: 2025 - 2025N - 2026 - 2027 - 2933

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A. LAST UPDATE: 25/06/2010 UPDATE NUMBER: 1

Installation, operation and maintenance instructions

1. Product description.....................................................................................................3

2. Transport and Storage conditions .............................................................................3

3. Valve breakdown..........................................................................................................4

3.1 Drawing and Components (Art. 2025 / 2025N / 2026 / 2027....................................4

3.2 Drawing and Components (Art. 2933)......................................................................5

4. Installation instructions ..............................................................................................6

4.1) Preparation..............................................................................................................6

4.2) Assembling..............................................................................................................7

5. Operating instructions ................................................................................................8

5.1) Usage......................................................................................................................8

5.2) Manual operation ....................................................................................................9

5.3) Remote operation....................................................................................................9

6. Maintenance instructions............................................................................................9

6.1) Stem leaks..............................................................................................................9

6.2) Body/edges joints leak............................................................................................9

6.3) Line leaks (through seats).....................................................................................10

7. Reparation instructions.............................................................................................10

7.1) Disassembling.......................................................................................................10

7.2) Reassembling .......................................................................................................12

8. Torques table:............................................................................................................13

9. Hygiene and Safety Instructions: .............................................................................14

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A. LAST UPDATE: 25/06/2010 UPDATE NUMBER: 1

1. Product description.

Genebre, S.A. offers a wide range of ball valves (90º turn), designed and assembled to

handle and drive fluids in industrial procedures.

The compatibility of materials used to build the valves (see technical specifications) and

the application of valves to the different industrial processes is at user's risk. Valves will

have an optimal behaviour when working conditions do not exceed pressure and

temperature limits (pressure curve) for which they have been designed.

2. Transport and Storage conditions

Transport and storage of this type of products must be done in their original

package

VISUAL INSPECTION

Check whether during transport, unloading and placement products have suffered any

damage.

Manual valves are provided by default in an open position whereas automated valves are

usually offered in a closed position due to the standard error position NC (normally

closed). During storage it is recommended to keep them in this same position, with the

included protective wrapping to avoid damages or dirt accumulation in the ball. The wrap

must not be removed until valve is to be installed.

When possible, valves must be stored in a dry and clean environment.

If you notice any kind of anomaly during reception of the goods, contact immediately

with GENEBRE in order to determine the possible responsibilities on the issue.

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A. LAST UPDATE: 25/06/2010 UPDATE NUMBER: 1

IMPORTANT NOTE:

Before installing and/or manipulating these elements READ CAREFULLY the

enclosed instructions for use and OBSERVE all contained information. If any of

the contents is not clear enough, please contact GENEBRE, S.A.

User is responsible for the safe use of these products, as established in

present instructions for use and in the specific technical documentation of the

supplied device.

3. Valve breakdown

3.1 Drawing and Components (Art. 2025 / 2025N / 2026 / 2027)

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A. LAST UPDATE: 25/06/2010 UPDATE NUMBER: 1

Part Nr. Description Quant. Material

Spare part

(kit ref.)

1 BODY 1 AISI 316

2 COVER 2 AISI 316

3 BALL 1 AISI 316 2907

4 STEM 1 AISI 316 2905

5 SEAT 2 PTFE+15%FV

2820

6 JOINT 2 PTFE+GRAPH

2820

7 FRICTION WASHER 1 PTFE+GRAPH

2820

8 O-RING 1 VITON 2820

9 PACKING 1 PTFE 2820

10 STUFFING BOX 1 AISI 316

11 SPRING WASHER 2 AISI 301

12 NUT 2 AISI 316

13 LOCK NUT 1 AISI 304

14 STOPPER 1/4 - 2" 1 AISI 304

15 HANDLE 1 AISI 304

16 WASHER 1 AISI 304

17 COVER 1 VINIL

18 SCREW/BOLT 4 / 6 AISI 304

19 WASHER 4 / 12 AISI 304

20 NUT 4 / 12 AISI 304

21 STOPPER 2 1/2"- 4" 1 AISI 304

3.2 Drawing and Components (Art. 2933)

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A. LAST UPDATE: 25/06/2010 UPDATE NUMBER: 1

4. Installation instructions

4.1) Preparation

Remove any material remains of the valve wrapping.

Serious problems may arise with the installation of a valve in a dirty pipe.

Make sure the pipe is not dirty and doesn’t have welding particles, for example, before

installing it. This may cause irreparable damages in the valve when the equipment is

started → prepare a clean working area.

Plan beforehand enough space for future maintenance operations.

Check correct performance of the valve by turning the handle clockwise and making sure

the ball closes the fluid flow. If this is not the case, check if there are foreign particles

inside the valve and repeat the whole operation.

Part.

Nr Description Quant. Material Spare part

(ref.)

1 Body 1 CF8M ----

2 Cover 2 CF8M ----

3 Ball 1 316 ----

4 Seat 2 PTFE 2912

5 Screw 4 A193-B7 ----

6 Stem 1 316 ----

7 Antiestatic Device 2 316 ----

8 Friction washer 1 PTFE 2912

9 O-ring 1 Viton 2912

10 Packing 1 PTFE 2912

11 Washer 1 PTFE+INOX 2912

12 Stem Ring 1 304 ----

13 Belleville Washer 2 301 ----

14 Stem nut 1 304 ----

15 Lock nut 1 304 ----

16 Washer 1 304 ----

17 Handle nut 1 304 ----

18 Handle 1 304 ----

19 Lock Device 1 304 ----

20 Handle cover 1 Plastic ----

21 Gasket 2 PTFE 2912

22 Washer 4 304 ----

23 Nut 4 A194-8 ----

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A. LAST UPDATE: 25/06/2010 UPDATE NUMBER: 1

4.2) Assembling

- Art. 2025 / 2025N (threaded ends valve)

Do not disassemble the valves to install them.

Make sure the valve's pipe and thread ends are clean and are compatible one with

another. Apply an appropriate seal in the pipe threads and screw in the valve, being

careful not to tighten too much the conical threads.

Do not use the valve handle as a lever to screw the valve into the pipe.

To tighten the valve, it is recommended to use a spanner or a monkey wrench applying

force only on the hexagonal edges of the valve. It is also recommended this force to be

inferior to 30 Nm.

- Art. 2026 / 2027 (welded ends valve)

a) With the valve in a OPEN position, remove the screws (part.18), washers (part.19),

nuts (part. 20) and connection edges or cover (part.2).

b) Turn the ball until reaching the half-open position and remove the seats (part.5) and

joints (part.6) of the body (part.1) carefully. Complete the turn until closing the valve and

extract the ball (part.3). All components must be stored in a dry and clean environment.

c) Assemble back the valve edges or cover (part.2) into the body, keeping them aligned

as much as you can, using only 2 screws (part.18) diagonally opposed. Weld in least 4

different points (cross-shaped).

d) Remove the body (part.1) from the valve edges (to avoid welding temperature to

damage rod washers) and complete the welding process by making sure the covers

(part.2) are protected against welding metal spatters.

When cold, clean the edges' locking surfaces. Place the ball (part.3), seats (part.5) and

joints (part.6) on the valve's body and turn the ball into open position.

Place the valve's body between the 2 edges being careful not to scratch contact surfaces;

then, place the screws (part.18) screwing them in diagonally opposed to each other and

respecting the specified torque or peer (see Section 8.3).

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A. LAST UPDATE: 25/06/2010 UPDATE NUMBER: 1

- Art. 2933 (clamp ends valve)

It is not necessary to disassemble the valve in order to install it.

Make sure the pipe’s clamp and the cover (part.2) clamp are clean. Place the silicone

joints (art. 2987-Genebre) between the clamp ends to keep them tight and join them

together with a quick locking binding clamp (art. 2986-Genebre). There is a different joint

and binding for each valve size.

IMPORTANT INFORMATION:

Design of this type of ball bore valves allows us to install them in any position as

they are bidirectional, so the direction of fluid flow does not matter.

If possible, it is recommended to install the valve in horizontal position and the

stem (handle) upwards.

Valves do not have to support pipe's efforts so it is advisable to anticipate a good

alignment and parallelism of such pipe.

Once installed, it is recommended to open and close it a couple of times to verify

its good performance and to check if there is any obstruction in the ball that

prevents it from closing.

It is also recommended to use filters in the pipe to extend lifecycle of the valve.

5. Operational instructions

5.1) Usage

3 pieces full bore ball valves provide a leakproof lock when used adjusted to the pressure

and temperature values for which they have been designed.

Avoid by all means to leave the valves in partially open position if you are not aware of

the pressure drop and flow rate in that position, as the service life of the seat can be

reduced and/or it can be damaged due to the ball bore valve.

Any fluid that can be solidified, crystallized or polymerized should not remain in the ball

cavity as it is harmful for performance, service life of the valve and it can even render it

unusable.

Seats for the valve, joints, body, ball, stem and ends have to be fully compatible with the

fluid circulating through the valve. Otherwise, valve could be seriously damaged.

Torques required to operate valves are listed on the table in section 8.1.

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A. LAST UPDATE: 25/06/2010 UPDATE NUMBER: 1

5.2) Manual operation

When operating the valve you must avoid excessive lateral efforts with the handle.

To close it, you must turn the handle 90 degrees clockwise. When the handle is inline

with the pipe, valve is open.

In case you need to remove the handle to automate the valve, the stem (part. 4) has a

mechanized linear mark at the front part that allows us to know its current position

(opened or closed).

5.3) Remote operation

When automation of 3 piece valves is required, GENEBRE S.A. can provide a great

variety of pneumatic actuators, electric actuators, electropneumatic and electronic

positioners to cover a large range of operations.

6. Maintenance instructions

Frequency, location and process of maintenance will be determined by the user by taking

into account usage of the product. However, periodical checks explained below will be

useful to extend the service life of the valve and reduce installation problems:

Valves must not remain in open or closed position for a long period of time. It is

recommended, if the process allows for it, to proceed to an operational task for the valve

every six months.

6.1) Stem leaks

Remove the handle or actuator, the lock nut washer (part.13 / part.15 Art.2933) and

tighten the nut (part.12 / part.14 Art.2933) of the stem packing (see Section 8.2). If the

leak persists, valve should be disassembled to replace the stem washers (part.7,8,9 /

part.8,9,10,11 Art.2933).

See reparation instructions.

6.2) Body joints/edges leaks

Check if the body screws (part.18 / part.5 Art.2933) are tightened. If they were loose,

adjust them up until the recommended torques (IMPORTANT: adjustment of such screws

will have to be done at room temperature). If leak continues, it is probably due to a

damage int he body's joint or the locking surface, and it will be necessary to disassemble

the valve to repair it.

See reparation instructions.

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A. LAST UPDATE: 25/06/2010 UPDATE NUMBER: 1

6.3) Line leaks (through seats).

Check if the valve is in a completely closed position. If this is the case, leak is due to

a seat or locking surface being damaged and it will be necessary to disassemble the

valve for repairing it.

See reparation instructions.

7. Reparation instructions

7.1) Disassembling

To proceed to repair it, it is not necessary to remove the valve from the installation as the

3-pieces design for the valve allows us to remove the central part (body with all internal

components) without having to disassemble the terminals.

Prepare a clean working area and adequate tools to perform mechanical tasks.

a.- Place the valve in an OPEN position to avoid

the ball from standing out of the body and interfere

with the ends when the body is removed.

Remember that the stem has a line in the frontal

part to indicate position of the valve:

parallel to pipe → open valve,

perpendicular to pipe → closed valve,

Before disassembling the pipe's valve to repair or replace it, make sure that line

has been closed and depressurized because a bad operational procedure could

cause a serious accident to you or to the installation system

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