Genebre 2528V User manual

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INSTALLATION, OPERATION AND MAINTENANCE
MANUAL
“V”control ball valve, direct mount
Flanged ends
Ref. GENEBRE: 2528V

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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

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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, 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.

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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

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Nº
Name
Material
Surface
Treatment
Spare
Part Code
1
Body
Stainless Steel 1.4408
Shot blasting
------
2
Cap
Stainless Steel 1.4408
Shot blasting
------
3*
Ball
Stainless Steel 1.4408
------
2907V xx xx
4*
Stem
/ Stainless Steel AISI 316
------
2908
5*
Ball Seat
PTFE+15% GF
------
2909
6*
Gasket
PTFE + Graphite (until DN25)
SS+Graphite (from DN32)
------
2909
7*
Thrust Washer
PTFE + graphite
------
2909
8*
O’ ring
FKM
------
2909
9*
Stem packing
PTFE
------
2909
10
Gland
Stainless Steel AISI 304
------
------
11
Spring Washer
Stainless Steel AISI 301
------
------
12
Nut
Stainless Steel AISI 304
------
------
13
Washer
Stainless Steel AISI 304
------
------
14
Stopper
Stainless Steel AISI 304
------
------
15
Handle
Stainless Steel AISI 304
------
------
16
Handle Sleeve
Vynil
------
------
17
Nut
Stainless Steel AISI 304
------
------
18
Stud Bolt
Stainless Steel AISI 304
------
------
19
Lock Washer
Stainless Steel AISI 304
------
------
20
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
13
Washer
Stainless Steel AISI 304
------
14
Stopper
Stainless Steel AISI 304
------
21
Body handle
Stainless Steel 1.4308
Shot blasting
22
Pin
Stainless Steel AISI 304
------

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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.

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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.

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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!

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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

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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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Remember that the STEM has a line in the frontal part to indicate position of the valve:
parallel to the pipe means open; perpendicular means closed.
b. - Loosen and remove the nuts (part. 17) on the studs (part. 18) that bring together the
two different parts of the valve.
Be careful not to damage the sealing surfaces.
c. - Remove the cap (part. 2) and the seat (part. 5) and gasket (part. 6) located inside the
body.
d. - Remove the ball (part. 3) from the body (part. 1). This operation has to be performed
carefully, otherwise the ball could be marked against the body.
e. - Then, remove the other seat (part. 5) located inside the body. It should be removed
with care, to avoid scratching or damaging the mechanized surfaces over which it is
hermetically sealed.
f.-To disassemble the STEM (part. 4), remove the following elements:
•Handle nut (part. 12).
•Washer (part, 13).
•Handle (part. 15).
•Stopper plate (part.14)
•Locking washer (part. 19).
•Nut (part. 12).
•Spring washers (part. 11).
•Stem Ring (part. 10)
Push the STEM to the inside part of the body and remove it. Then, remove the packing
(part. 9) located inside the body.
Remove the o-ring (part. 8) from its location and also remove the thrust washer (part. 7).
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) Rebuilding (assembling 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 for the valve.
a. - Place a new thrust washer (part. 7) on the STEM (part. 4) and also the o-ring (part. 8)
in its corresponding location on the STEM. 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 packing (part. 9) in its location. In the upper cavity of the body (part.1),
the gland (part. 10) and the Belleville 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 observing the torque specified value (See Torque table).
If necessary, fasten with a wrench the internal body of the STEM to tighten the nut
properly 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 the lock washer (part.19) later on.
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 a closed valve position and insert the ball (part. 3) inside the body
(part. 1) by matching the ball slot with STEM groove (part. 4).
d. - New seats (part. 5) and body gasket (part.6) can be placed on both sides of the
valve, body (part. 1) and cap (part. 2) taking into account that the flat side of the seat
must be facing downwards.
e.- Place the cap (part. 2) over the body (part. 1) matching the external flange holes;
place the nuts (part. 17) on the studs (part. 18) to bring together the two different parts of
the valve.
f.- Then, tighten the nuts (part. 17) adjusting slowly and alternating diagonally and evenly
until obtaining the recommended tightening torque (see Torque table).

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8.) Torque table:
8.1) Torques to operate the valves:
SIZE
Max. torque (N·m)
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
5”
130 - 150
6”
190 - 210
8”
380 - 410
8.2) Tightening torque for the STEM nut:
Following numerical data is provided as reference only. Specified torques
are the ones used to operate 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
5” -6” -8”
29 - 35
8.3) Tightening torque Screws/ Nuts for joining the valve's different parts:
It is required for all body screws to make contact of body metal against cover metal.
Screws / Nuts
Tightening Torque
N.m
M8
25
M10
50
M12
87
M14
138
M16
210
M20
412

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(These values are the recommended values by screws manufacturers, in our case we
have considered using them in cal. 8.8)
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) 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 should be performed in ventilated places.