Genebre 2052 User manual

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GENEBRE S.A.
LAST UPDATE: 23/03/2020 UPDATE NUMBER: 2
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INSTALLATION, OPERATION AND MAINTENANCE
MANUAL
3 pc full bore ball valve, direct mount, with bottom tank flange
GENEBRE Reference: 2052 –2053

Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
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GENEBRE S.A.
LAST UPDATE: 23/03/2020 UPDATE NUMBER: 2
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Installation, operation and maintenance instructions
1. Product description.......................................................................................................3
2. Transport and Storage conditions.................................................................................3
3. Breakdown and valve components...............................................................................4
4. Installation instructions .................................................................................................5
4.1) Preparation............................................................................................................5
4.2) Assembling............................................................................................................5
5. Operating instructions...................................................................................................8
5.1) Usage....................................................................................................................8
5.2) Manual operation...................................................................................................8
5.3) Remote operation ..................................................................................................8
6. Maintenance instructions..............................................................................................9
6.1) Stem leaks.............................................................................................................9
6.2) Body/Caps joints leak ............................................................................................9
6.3) Line leaks (through seats)......................................................................................9
7. Reparation instructions...............................................................................................10
7.2) Reassembling......................................................................................................11
8. Torques table: ............................................................................................................12
9. Hygiene and Safety Instructions:................................................................................13

Genebre Building. Av. de Joan Carles I, 46-48
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LAST UPDATE: 23/03/2020 UPDATE NUMBER: 2
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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. Please, refer to
the product datasheet.
Art. 2052: Ball valve with bottom tank flange and threaded end ISO 7/1
Art. 2053: Ball valve with bottom tank flange and Butt-Welding end
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 the products have suffered
damages.
Manual valves are provided by default in a open position whereas automated valves
usually are 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.
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.

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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. Breakdown and valve components

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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.
Control correct operation 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
- TANK FLANGE
Part
num.
Description
Quant.
Material
Replacement
(ref.)
1
Body
1
1.4408
----
2 a
Tank flange
1
1.4404 (316L)
----
2 b
Caps
1
1.4408
----
3
Ball
1
1.4408
2907 (2904 f/DN100)
4
Stem
1
Inox AISI 316
2905
5
Seat
2
Teflon + 15% FV
2820
6
Joint
2
Teflon + graphite
2820
7
Friction washer
1
Teflon + graphite
2820
8
O'ring
1
Viton
2820
9
Wrapping
1
PTFE
2820
10
Gland nut
1
Inox AISI 304
----
11
Belleville Washer
2
Inox AISI 301
----
12
Nut
2
Inox AISI 304
----
13
Washer
1
Inox AISI 304
----
14
Stopper
1
Inox AISI 304
----
15
Screw
4 / 6
Inox AISI 304
----
16
Grover washer
4 / 6
Inox AISI 304
----
17
Handle
1
Inox AISI 304
----
18
Caps
1
Vinyl
----
19
Stopper pin
1
Inox AISI 304
----

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a) With the valve in OPEN position, remove the screws (part 15), washers (part 16) and
the connecting caps (part 2a and 2b).
b) Place the tank flange (part 2a) in the previously location on the deposit bottom, fitting
the caps diameter (D) with the deposit diameter. The height G should also fit the thickness
of the deposit sheet. Take into account that those measures vary depending on the size of
the valve to be installed.
c) Once it is placed in the deposit, proceed
to weld it being extremely careful
not too rise too much the flange
temperature, as it can experiment a
deformation.
Make sure the opposite side of the flange
(part 2a) is protected against welding metal
spatters.
d) After welding the tank flange (part 2a), once it is already cold, clean the edges' locking
surfaces.
e) Place the valve's body between the 2 edges being careful not to scratch
contact surfaces; then, place the screws (part 15) and their corresponding washers (part
16) screwing them diagonally opposed to each other and observing the specified torque
(see Section 8.3).
- Opposite side to the tank flange
- Threaded end (Article 2052)
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 into the pipes' thread ends and thread
the valve.
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 spanner or monkey wrench only on the
hexagonal area of the valves edges, the torque applied being less than 30 Nm.
- Welding cap (Article 2053)
a) With the valve in OPEN position, remove the screws (part 15), washers (part 16) and
the connecting cap (part 2b).

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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) Reassemble the valve keeping aligned (if possible) the tank flange (part 2a), body (part
1) and caps (part 2b), using only 2 diagonally opposed screws (part 15). Weld at least in 4
different points (cross-shaped) between the caps (part 2b) and the pipe.
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 flat side of
the caps (part 2b) is 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
the contact surfaces; then, place the screws (part 15) with their corresponding washers
(part 16), screwing them diagonally opposed to each other and respecting the specified
torque or peer (see Section 8.3).
IMPORTANT INFORMATION:
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.
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 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.

Genebre Building. Av. de Joan Carles I, 46-48
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5. Operating instructions
5.1) Usage
3 piece 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 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, stem and ends have to be fully compatible with the
fluid circulating through the valve. Otherwise, the valve could be seriously damaged.
Torques required to operate valves are listed in the table Torques to activate the valves
(see 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 allow 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 electronical positioners to
caps a large range of operations.

Genebre Building. Av. de Joan Carles I, 46-48
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6. Maintenance instructions
Frequency, place 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 when necessary.
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 of the valve
every six months.
6.1) Stem leaks
Remove the handle or actuator, the lock nut washer (part 19) and tighten the nut (part 12)
of the stem packing (see Section 8.2). If the leak persists, valve should be disassembled to
replace the stem washers (parts 7,8,9).
See reparation instructions.
6.2) Body/Caps joints leak
Check if the body screws (part 15) are tightened. If they were loose, adjust them up until
the recommended torque values (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.
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.

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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 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,
b.- Loosen and remove the 4 / 6 nuts (part 15) that bring together the three different parts
of the valve.
Be careful not to damage the edges surfaces.
c.- Remove the central group separating it from the capss (part 2a and 2b).
d.- Once the body is out, place the ball (part 3) in a half-open position (45º, for example)
and remove the seats (part 5). Complete the turn of the ball until closed position and then it
can be removed. This operation has to be performed carefully, otherwise the vall can be
marked against the body.
e.- After this, remove the body's joints (part 6). They should be removed being carefully not
to scratch or damage the mechanized surfaces over which they are hermetically sealed.
f.-To disassemble the stem (part 4), remove the following elements:
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 staff and installation system

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Push the stem to the inside part of the body and remove it. Later, remove the packaging
(part 9) located inside the body. Remove the o’ring (part 8) from its location and the friction
washer (part 7).
g.- Once the valve is dismantled you must verify the state of each single piece that
compose it. All pieces to be reused have to be cleaned completely and be kept in a safe
and clean environment.
All locking surfaces in the ball, seats, joints and sides have to be checked for corrosion,
erosion, metallic inlays in the seats and marks. If they were damaged or in case of doubt,
they will need to be replaced.
h.- Cleaning of the valve's pieces must be done using an adequate degreasing agent. You
must be careful with the locking surfaces, for example, of the ball, locking sides of the ends
and joints, because if they were damaged this could cause a bad impact in the valve's
performance.
7.2) Reassembling
Before proceeding to reassemble the valve, make sure that reparation kit and/or pieces to
be used are appropriate and original from the factory.
When it is armored again, cleaning is essential for a long life for the valve.
a.- Place a new friction washer (part 7) on the stem (part 4) and also the o’ring (part 8) in
its stem corresponding location, lubricate the stem with a thin layer of grease or silicon (for
example, Dow Corning 200) and insert it in the valve's body (part 1), in the internal cavity,
by pushing a bit to fix it.
b.- Place a new packaging (part 9) into its location in the upper cavity of the body (part 1),
the gland nut (part 10) and the spring washers (part 11) with external borders together
(concave position). Place the nut (part 12) and tighten it. Make the stem turn a couple of
times and readjust the nut respecting the torque specified value (See Section 8.2).
Name
Art. 2052 / 2053
Handle nut
Part.12
Dividing washer
Part.13
Handle
Part.17
Lock nut
Part.19
Nut
Part.12
Spring washers
Part.11
Gland nut
Part.10

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If necessary, fasten with a wrench the internal body of the stem to tighten properly the nut
without making the stem turn.
It is convenient to match one of the nut vertexes with one of the stem vertexes to be able
to place it later on the lock nut (part 19).
Note that if the nut is too tight, the rod torque will increase and service life of its elements
will be reduced.
c.- Place the stem in closed valve position and insert the ball (part 3) inside the body (part
1) matching the ball slot with stem milling (part 4). Open the valve so that the ball does not
fall.
d.- New seats (part 5) and body joints (part 6) can be placed now on both sides of the
body, taking into account that the flat part of the seat needs to be facing outwards.
e.- Terminals or caps (part 2a and 2b) need to have locking parts cleaned before
proceeding to final assembly.
Place the central core of the valve between the terminals and place the corresponding
screws (part 15) and the Belleville washers (part 16) to bring together the three different
parts of the valve.
Now it is important that pieces as the stoppers (part 2a and 2b) the ball (part 3) and seats
(part 5) are completely aligned inside.
f.- Then, proceed to place the nuts (part 15) adjusting slowly and alternating diagonal and
evenly until obtaining the recommended tightening torque (see Section 8.3).
8. Torques table:
8.1) Torques to activate the valves:
SIZE
Activating torque (N·m)
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 ½”
34 –36
3”
58 –60
4”
90 –95

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8.2) Tightening torque for stem nut:
Following numerical data is provided as reference only. Torques mentioned are the ones
used to activate the assembled stem before ball and seats are assembled.
Valve size
Torque value (N.m.)
1/4" - 3/8” -1/2"
6 - 9
3/4" - 1”
8 - 12
1 ¼” -1 ½” -2”
13 - 18
2 ½” -3” -4”
19 - 24.5
8.3) Tightening torque for screws/nuts that join the valve's three different parts:
It is required for all body screws to make contact metal with metal between the body
terminals and the caps.
Valve size
Screw / Nut
Torque value (N.m.)
1/4" - 3/8” -1/2"
M6
8 - 11
3/4" - 1”
M8
13.5 - 16
1 ¼” -1 ½” -2”
M10
22 - 25
2 ½” -3” -4”
1/2" W
74.5 - 81
9. Hygiene and Safety Instructions:
9.1) Fluids that go through a valve can be corrosive, toxic, flammable or pollutant. They
can also be found at very high or low temperature. 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.
Before removing a valve from a pipe, always check if the line is completely
drained and depressurized.
9.2) Operate the valve in open position to make sure there is no pressure in the internal
cavity.

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9.3) Any valve being used by toxic services department needs to obtain a cleanliness
certificate before being operated.
9.4) Any type of repair or maintenance should be performed in ventilated places.