Genebre 2528V Manual de usuario

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

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

FECHA DE REVISIÓN: 02/09/2020 NUMERO DE REVISIÓN: 0

INSTALLATION, OPERATION AND MAINTENANCE

MANUAL

“V”control ball valve, direct mount

Flanged ends

Ref. GENEBRE: 2528V

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

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

FECHA DE REVISIÓN: 02/09/2020 NUMERO DE REVISIÓN: 0

Installation, operation and maintenance instructions

1. Products description .................................................................................... 3

Atex Technical data ………………………………………………………. 3

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

3. Valve Breakdown ....................................................................................... 4

4. Installation Instructions

4.0 Atex Installation ………………………………………….……………….. 6

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

4.2 Installation ................................................................................................... 6

5. Operating Instructions

5.1 Usage ......................................................................................................... 7

5.2 Manual Operation .......................................................................................... 8

5.3 Remote Operation .......................................................................................... 8

6. Maintenance Instructions

6.0 Inspection and Atex maintenance requirements …………………………… 8

6.1 Stem Leaks .................................................................................................... 9

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

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

7. Repair Instructions

7.0 Atex Repair requirements ..………………………..…………………... 10

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

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

8. Torques Table ........................................................................................... 13

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

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

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

FECHA DE REVISIÓN: 02/09/2020 NUMERO DE REVISIÓN: 0

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. Please, refer to

the product data sheet.

ATEX TECHNICAL DATA

CE custody file: LOM 11ATEX0067

ATEX Classification: II 2 GD

Type of protection: Constructional safety “c”

Termal Class: T6 to T3 according to the fluid inside

T amb. of use: -20ºC a/to +60ºC

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.

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

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

FECHA DE REVISIÓN: 02/09/2020 NUMERO DE REVISIÓN: 0

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.

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

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

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

FECHA DE REVISIÓN: 02/09/2020 NUMERO DE REVISIÓN: 0

Nº

Name

Material

Surface

Treatment

Spare

Part Code

Body

Stainless Steel 1.4408

Shot blasting

------

Cap

Stainless Steel 1.4408

Shot blasting

------

Ball

Stainless Steel 1.4408

------

2907V xx xx

Stem

/ Stainless Steel AISI 316

------

2908

Ball Seat

PTFE+15% GF

------

2909

Gasket

PTFE + Graphite (until DN25)

SS+Graphite (from DN32)

------

2909

Thrust Washer

PTFE + graphite

------

2909

O’ ring

FKM

------

2909

Stem packing

PTFE

------

2909

Gland

Stainless Steel AISI 304

------

Spring Washer

Stainless Steel AISI 301

------

Nut

Stainless Steel AISI 304

------

Washer

Stainless Steel AISI 304

------

Stopper

Stainless Steel AISI 304

------

Handle

Stainless Steel AISI 304

------

Handle Sleeve

Vynil

------

Nut

Stainless Steel AISI 304

------

Stud Bolt

Stainless Steel AISI 304

------

Lock Washer

Stainless Steel AISI 304

------

Antiestatic Device

Stainless Steel AISI 304

------

* Available spare parts

** Configuration of “V”ball: 30º - 60º or 90º

Only in sizes from 2 ½” to 8”

Nº

Name

Material

Surface Treatment

Washer

Stainless Steel AISI 304

------

Stopper

Stainless Steel AISI 304

------

Body handle

Stainless Steel 1.4308

Shot blasting

Stainless Steel AISI 304

------

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

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

FECHA DE REVISIÓN: 02/09/2020 NUMERO DE REVISIÓN: 0

4. Installation instructions

4.0) ATEX Installation

These ball valves are suitable to be set up in explosive atmospheres:

Zones 1 and 2 according to IEC 60079-10-1, of application without limitation by

gas subgroup and whose auto-ignition temperature of the surrounding explosive

atmosphere is as marked on the valve as follows:

Thermal class marked Max auto-ignition temperature

T6 < 80ºC

T5 > 80ºC < 95ºC

T4 > 95ºC < 130ºC

T3 > 130ºC < 190ºC

Zones 21 and 22 according to IEC 60079-10-2, whose self-ignition temperature

is ≥ 130ºC in combustible dust clouds, and ≥ 125ºC in layers of dust with a maximum

thickness of 5 mm.

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.

In case of vibrations in the pipe it is strongly recommended to mount anti-vibration

elements to absorb them. Otherwise, the life of the product could be drastically reduced.

4.2) Assembling

Do not disassemble the valves to install them.

Make sure the pipe's and edges flanges of the valve are clean.

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

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

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GENEBRE S.A.

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Use the corresponding screws in all of the flanges drill holes.

Place an adequate joint in each end and align it in the centre of the flanges.

Tighten screws evenly and cross-shaped to avoid deformations. To do so, you must not

force in any case the pipe to centre the valve; it should take its position smoothly. Last,

verify that screws are tightened with the recommended torque for each type of screw.

Make sure the flanges joints are well placed.

After assembling, check the tightness and performance of the valve.

IMPORTANT INFORMATION:

Design for this kind of regulation valves allows only one position for assembling it

to the pipe, specified by means of an arrow in the valve's body that indicates the

direction in which the fluid needs to circulate.

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

The ball valves provide a leak proof lock when used adjusted to the pressure and

temperature values for which they have been designed.

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.

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

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

FECHA DE REVISIÓN: 02/09/2020 NUMERO DE REVISIÓN: 0

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.

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 ball 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

6.0) Inspection and Atex maintenance requirements

¡National regulations about maintenance, service, inspection and repair of

equipment in locations with explosive atmospheres, as well as general rules of

engineering, must be observed!

A defective or incomplete maintenance can bear a malfunctioning of the

equipment.

A good maintenance will allow reducing the incidences of the process (costs of the

“no quality”) and will guarantee, at the same time, the fulfillment of the

requirements of security and specifications of the product!

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

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

FECHA DE REVISIÓN: 02/09/2020 NUMERO DE REVISIÓN: 0

It is responsibility of the user to establish a plan of inspection and maintenance of these

apparatuses with the purpose of guaranteeing its safe use.

The inspections must be made only by qualified personnel, in accordance with the type of

equipment and installation required.

It is possible to follow the standard UNE-EN 60079-17 as a guide, in order to carry out a

plan of inspection in facilities with potentially explosive atmospheres.

Regarding to the reparation of the equipment, it is advised to follow the requirements of

the standard UNE-EN 60079-19.

¡When the inspections are classified as “Detailed” grade, or in some cases as

“Near” grade, the equipment must be totally out of service!

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:

The valves should not be left in the open or closed position for a long period of time, it is

recommended as long as the process allows a maneuvering operation of the valve at

least every six months.

6.1) Stem leakage

Remove the handle or actuator, the locking nut washer (part. 19) and tighten the nut

(part. 12) of the STEM packing. If the leak persists, valve should be disassembled to

replace the STEM washers (part.7,8,9).

See reparation instructions.

6.2) Body/Cap joint leakage

Check if the union nuts between body and cover (part. 17) 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

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

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

FECHA DE REVISIÓN: 02/09/2020 NUMERO DE REVISIÓN: 0

some damage in the body's joint or the locking surface and it will be necessary to

disassemble the valve to repair it.

See reparation instructions.

6.3) Line leakage (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 to repair it.

See reparation instructions.

7. Reparation instructions

7.0) ATEX repair requirements

Regarding to the reparation of the equipment, it is advised to follow the requirements of

the standard UNE-EN 60079-19.

¡Use only original spare parts or recommended by GENEBRE, SA!

7.1) Disassembling

You must remove the valve from its installation to repair it, making sure the pipe has

been previously depressurized.

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

a. - Place the valve in closed position to impede the ball from damaging seats when

disassembling.

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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