Genebre 2009 User manual

Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
[email protected] - www.genebre.es
GENEBRE S.A. LAST UPDATE: 25/06/2010 UPDATE NUMBER: 0
1
INSTALLATION, OPERATION AND MAINTENANCE
MANUAL
2 piece full bore ball valve
with threaded ends
GENEBRE Reference: 2009 – 2010 – 2014 – 2014N

Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
[email protected] - www.genebre.es
GENEBRE S.A. LAST UPDATE: 25/06/2010 UPDATE NUMBER: 0
2
Installation, operation and maintenance instructions
1. Product description.................................................................................... 3
2. Transport and Storage conditions ............................................................. 3
3. Installation instructions .............................................................................. 4
3.1) Preparation.......................................................................................... 4
3.2) Assembling.......................................................................................... 4
4. Operating instructions................................................................................ 5
4.1) Usage.................................................................................................. 5
4.2) Manual operation................................................................................. 5
5. Maintenance instructions........................................................................... 6
6. Reparation instructions.............................................................................. 6
7. Activating torques table: ............................................................................ 7
8. Hygiene and Safety Instructions................................................................ 7

Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
[email protected] - www.genebre.es
GENEBRE S.A. LAST UPDATE: 25/06/2010 UPDATE NUMBER: 0
3
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 behavior 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 kind of products must be done keeping them in their
original package!
VISUAL INSPECTION
Check whether during transport, unloading and placement, products have suffered
damages.
Manual valves come by default in open position. 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 dial. The wrap must not be removed until valve is to be
installed.
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)
[email protected] - www.genebre.es
GENEBRE S.A. LAST UPDATE: 25/06/2010 UPDATE NUMBER: 0
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IMPORTANT NOTE:
Before installing and/or manipulating these elements, READ CAREFULLY these
instructions for use and OBSERVE all contained information. If you fail to
understand any of their content, please contact GENEBRE, S.A.
User is responsible for the safe use of these products, according to present
instructions for use and specific technical documentation of the device.
3. Installation instructions
3.1) 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.
Control correct operation of the valve by turning the handle clockwise and making sure
the dial closes the fluid flow. If this is not the case, check if there are foreign particles
inside the valve and repeat the whole operation.
3.2) Assembling
Make sure the valve's pipe and thread end are clean and are compatible one with
another (type of thread end) Apply an appropriate sealing in the pipes' thread ends and
thread the valve being careful not to excessively tighten the conical threaded ends.
Do not use valve's handle as a lever to thread the valve into the pipe.
To tighten the valve it is recommended to use a flat or monkey wrench only on the
hexagonal area of the valves edges; the force applied being less than 30 Nm.
Design of this kind 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.

Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
[email protected] - www.genebre.es
GENEBRE S.A. LAST UPDATE: 25/06/2010 UPDATE NUMBER: 0
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If possible, it is recommended to install the valve in horizontal position and the axis
(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
knowledge 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.
4. Operating instructions
4.1) Usage
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 leaving 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, axis 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 in the table Torques to activate the valves
(see Section 7).
4.2) 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.

Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
[email protected] - www.genebre.es
GENEBRE S.A. LAST UPDATE: 25/06/2010 UPDATE NUMBER: 0
6
5. Maintenance instructions
Frequency, place and process of maintenance will be determined by the user by taking
into account usage of the product. However, checks explained below will be useful to
extend the service life of the valve and reduce installation problems.
5.1) 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 operate it for control purposes every six
months.
5.2) Verify possible leaks in the axis area; in case they exist, proceed to tighten the
gland nut. If leak persists, valve should be replaced (see section 6).
5.3) Verify possible leaks through the line (seats); this defect is probably caused by
deposition of impurities between ball and seat, transported by the fluid. Disassemble the
valve from the pipe, clean it and reinstall it. If the problem persists you should change the
valve (see section 6).
5.4) Increase of operational torque; this defect is probably caused by deposition of
impurities between ball and seat, transported by the fluid. Disassemble the valve from the
pipe, clean it and reinstall it. If the problem persists you should change the valve (see
section 6).
6. Reparation instructions
This type of valves, due to their easy assembling and reduced production cost are not
worth repairing, because most of the times is simply not cost-effective, so we recommend
to directly replace it.
Before disassembling the pipe's valve to clean or replace it, make sure that line
has been closed and depressurized because a bad operational procedure could
cause a serious accident to staff and installation system
Before installing new valve, check if it meets the requirements of the valve
being replaced.

Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
[email protected] - www.genebre.es
GENEBRE S.A. LAST UPDATE: 25/06/2010 UPDATE NUMBER: 0
7
7. Activating torques table:
MEASURE Activating torque (Nm)
1/4” 4 – 5
3/8” 4 – 5
1/2" 4 – 5
3/4" 7 – 8
1” 9 – 10
1 ¼” 12 – 14
1 ½” 18 – 20
2” 28 – 30
2 1/2” 34 – 36
3” 58 – 60
8. Hygiene and Safety Instructions
8.1) Fluid passing through a valve or accessory can be corrosive, toxic, flammable or
pollutant. When operating valves, you must follow the security instructions and it is
recommended to use personal protection gadgets:
1) Protect your eyes.
2) Wear gloves and appropriate working clothes.
3) Wear safety footwear.
4) Wear a helmet.
5) Have running water at hand.
6) To operate flammable fluids, make sure you have an extinguisher at hand.
8.2) Before removing a valve from a pipe, check always if the line is completely drained
and depressurized.
8.3) Operate the valve in open position to make sure there is no pressure in the internal
cavity.
8.4) Any valve being used by toxic services department needs to obtain a cleanliness
certificate before being operated.