Genebre 2105 User manual

Edificio Genebre. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
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GENEBRE S.A.
FECHA DE REVISIÓN: 23/03/2020 NUMERO DE REVISIÓN: 2
1
INSTALLATION, OPERATION AND MAINTENANCE
MANUAL
Full bore ball valve Wafer type
Ref. GENEBRE: 2105 –2110 –2115 –2118 –2119

Edificio Genebre. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
[email protected] - www.genebre.es
GENEBRE S.A.
FECHA DE REVISIÓN: 23/03/2020 NUMERO DE REVISIÓN: 2
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Installation, operation and maintenance instructions
1. Products description .................................................................................... 3
2. Transport and Storage conditions ............................................................. 3
3. Valve Breakdown ....................................................................................... 4
4. Installation Instructions
4.1 Preparation ................................................................................................ 6
4.2 Installation ................................................................................................... 7
5. Operating Instructions
5.1 Usage ......................................................................................................... 8
5.2 Manual Operation .......................................................................................... 8
5.3 Remote Operation .......................................................................................... 8
6. Maintenance Instructions
6.1 Stem Leaks .................................................................................................... 9
6.2 Body/edges joints leak ................................................................................ 9
6.3 Line Leaks (through seats) ........................................................................... 9
7. Repair Instructions
7.1 Disassembling ............................................................................................... 9
7.2 Reassembling .......................................................................................... 11
8. Torque Tables .............................................................................................. 11
9. Hygiene and Safety Instructions ................................................................ 12

Edificio Genebre. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
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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 behaviour when working conditions do not exceed pressure and
temperature limits (pressure curve) for which they have been designed. Please, read the
data sheet of the product.
Art. 2105 Art. 2110 Art. 2115 Art. 2118 Art. 2119
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)
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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
Art. 2105/2110/2115

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*Repair Kit Parts
** Article 2115 has a heating jacket (or chamber). For further information please check
the data sheet of the product.
Art. 2118/2119
Nº
Denominación / Name
Material
Ref.
2105/2115**
2110
1
Cuerpo / Body
ASTM A105 (Painted)
AISI 316
-
2
Tapón / Plug
AISI 304
AISI 316
-
3*
Junta / Gasket
PTFE
PTFE
2925
4*
Bola / Ball
AISI 304
AISI 316
2809
(304)
2807
(316)
5*
Asiento / Ball Seat
PTFE
PTFE
2925
6*
Eje / Stem
AISI 304
AISI 316
I2110 (316)
7*
Arandela / Washer
PTFE
PTFE
2925
8
Prensa / Gland
Acero / Steel (Zn)
AISI 316
-
9
Arandela Resorte / Spring washer
Acero / Steel (Zn)
Acero / Steel (Zn)
-
10
Tope / Stopper
Acero / Steel (Zn)
Acero / Steel (Zn)
-
11
Pivote / Pin
Acero / Steel (Zn)
Acero / Steel (Zn)
-
12
Tuerca / Nut
Acero / Steel (Zn)
Acero / Steel (Zn)
-
13
Maneta / Handle
Acero / Steel (Zn)
Acero / Steel (Zn)
-
14
Funda / Sleeve
Vinyl
Vinyl
-

Edificio Genebre. Av. de Joan Carles I, 46-48
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Nº
Denominación / Name
Material
Acabado Superficial /
Surface Treatment
Ref
1
Cuerpo / Body
Acero Inox. / S.S. CF8M ( 316)
Decapado / Shot Blasting + Pickling
------
2
Tapón / Plug
Acero Inox. AISI 316 / SS 316
Decapado / Shot Blasting + Pickling
------
3*
Juntas / Gasket
PTFE
------
2818
4
Bola / Ball
Acero Inox. / S.S. CF8M ( 316)
------
------
5*
Asiento / Ball Seat
PTFE + 15 % F.V. / PTFE + 15 % G.F.
------
2818
6
Eje / Stem
Acero Inox. AISI 316 / SS 316
------
------
7*
Arandela / Thrust Washer
PTFE
------
2818
8*
Tórica / O-ring
Viton
------
2818
9*
A. Prensa / Stem packing
PTFE
------
2818
10
Prensa / Stem ring
Acero Inox AISI 304 / S.S. 304
------
------
11
Tuerca / Nut
Acero Inox AISI 304 / S.S. 304
------
------
12
Arandela Resorte / Spring washer
Acero Inox AISI 304 / S.S. 304
------
------
13
Antigiro / Lock Washer
Acero Inox AISI 304 / S.S. 304
------
------
14
Arandela / Washer
Acero Inox AISI 304 / S.S. 304
------
------
15
Tope / Stop Pin
Acero Inox AISI 304 / S.S. 304
------
------
16
Maneta / Handle
Acero Inox AISI 304 / S.S. 304
------
------
17
Funda / Plastic Cover
Vynil
------
*Repair Kit Parts
** Article 2119 has a heating jacket (or chamber). For further information please check
the data sheet of the product.
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.

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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 reduce them by expansion
joints or similar devices. 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.
Use the corresponding screws in all of the flanges drill holes.
Place an adequate joint in each end and align it in the center 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 center 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 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.
The thread connection of the heating chamber (art. 2115 / art. 2119) is G3/4"
according to ISO228.

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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.
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.
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.
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
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:

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6.1) Stem leakage
Remove the handle or actuator and tighten the Nut (part. 12 or part. 11 acc/ art.) of the
stem packing (see Section 8.2). If the leakage persists, valve should be disassembled to
replace the stem Washers (part.7 or part. 7 and 9 acc/ art.).
See reparation instructions.
6.2) Body gasket leakage
Check if the Plug (part. 2) is tightened. If it's loose, turn it clockwise (IMPORTANT:
adjustment will have to be done at room temperature). If leak continues, it is probably due
to 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
7.1) 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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b. - Loosen and remove the Plug (part. 2) turning counter-clockwise using a special tool.
Be careful not to damage the contact surfaces.
c. - Remove the Ball Seat (part. 5) and the Gasket (part. 3) located inside the Plug (part. 2).
d. - Remove the Ball (part. 4) from the Body (part. 1). This operation has to be performed
carefully, otherwise the ball could be damaged.
e. - Next, remove the other Ball Seat (part. 5) located inside the body. It should be
removed with care, to avoid scratching or damaging the machined surfaces over which it
is hermetically sealed.
f.-To disassemble the Stem (part. 6), remove the following elements:
(art. 2105/2110/2115) (art. 2118/2119)
•Handle and Sleeve (part. 13 and 14)
•Stem Nuts (part. 12)
•Stopper plate (part.10)
•Spring Washers (part. 9)
•Gland (part. 8)
•Stem Washers (part. 7)
•Handle and Sleeve (part. 16 and 17)
•Stem Nuts (part. 11)
•Lock Washer (part. 13)
•Spring Washers (part. 12)
•Gland (part. 10)
•Stem Washers (part. 7 and 9)
Push the stem towards the inside part of the body and remove it. Then, remove the stem
Washers and the Gland located inside the body.
g. - Once the valve is completely disassembled, you must verify the state of each one of
the pieces that compose it and the ones to be reused will have to be completely cleaned
and stored 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.

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7.2) Reassembling of the valve
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 assembled again, cleaning is essential for a long life of the valve.
a. - Place a new Washer (part. 7) on the Stem (part. 6), lubricate it 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.
b1.- (art. 2105/2110/2115) Place another new Washer (part. 7) in its location, in the upper
cavity of the Body (part.1), the Gland (part. 8) and the Spring Washers (part. 9) with
external borders together (concave position). Place the Stopper Plate (part. 10). Tighten
with the Nut (part. 12) and turn the stem a couple of times. Readjust the nut observing
the torque specified in Section 8.2.
b2.- (art. 2118/2119) Place another new Washer (part. 9) in its location, in the upper
cavity of the Body (part.1), the Gland (part. 10) and the Spring Washers (part. 9) with
external borders together (concave position). Tighten with the Nut (part. 11). Place the
Lock Washer (part. 13) and the Washer (part. 14). Turn the stem a couple of times.
Readjust the nut observing the torque specified in Section 8.2.
If necessary, fasten with a wrench the internal body of the stem to tighten the nut properly
without making the stem turn.
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 (part. 6) in a closed valve position and insert the Ball (part. 4) inside
the Body (part. 1) by matching the ball slot with the stem milling faces.
d. - New Ball Seats (part. 5) and Gasket (part. 3) can be placed on both sides of the
valve, Body (part. 1) and Plug (part. 2), taking into account that the flat side of the seat
must be facing downwards.
e.- Thread the Plug (part. 2) on the Body (part. 1) taking care of not damaging the raised
face of the flange.
f.- Assemble the Handle (part. 13 or part. 16 acc. to the art.) over the stem nut and fix
with the other available Nut.
8.) Torque table:
8.1) Breakaway torque of the valve:

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8.2) Tightening torque for the stem nut:
Following numerical data is provided as reference only. Specified torques
are the ones used to rotate the assembled stem before ball and seats
are assembled.
Valve size
Maximum torque (N.m.)
1/2" - 3/4" - 1”
8 - 12
1 ¼” -1 ½” -2”
13 - 18
2 ½” - 3” -4”
19 - 24,5
9. Hygiene and Safety Instructions:
9.1) Fluids that go through a valve can be corrosive, toxic, flammable or pollutant. And
they could be 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.
MEDIDA
Torque accionamiento N·m
DN15
4 –5
DN20
6 –8
DN25
8 –10
DN32
12 –14
DN40
18 –20
DN50
25 –30
DN65
32 –36
DN80
50 –60
DN100
85 –95

Edificio Genebre. Av. de Joan Carles I, 46-48
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Before removing a valve from a pipe, always check if the line is completely
drained and depressurized.
9.2) Always operate the valve in open position to make sure there is no pressure in the
internal cavity.
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 must be done in ventilated areas.