Genebre V Series User manual

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GENEBRE S.A.
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INSTALLATION, OPERATION AND MAINTENANCE
MANUAL
“V”control ball valve, 3 pieces direct mount
Threaded ends, Butt Weld and Socket Weld
GENEBRE Reference: 2025V –2025NV –2026V –2027V

Genebre Building. Av. de Joan Carles I, 46-48
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Installation, operation and maintenance instructions
1. Product description.....................................................................................................3
2. Transport and Storage conditions .............................................................................3
3. Valve breakdown..........................................................................................................4
3.1 Drawing and Components........................................................................................4
4. Installation instructions ..............................................................................................5
4.1) Preparation..............................................................................................................5
4.2) Assembling..............................................................................................................6
5. Operating instructions ................................................................................................7
5.1) Usage......................................................................................................................7
5.2) Manual operation ....................................................................................................8
5.3) Remote operation....................................................................................................8
6. Maintenance instructions............................................................................................8
6.1) Stem leakage..........................................................................................................8
6.2) Body/Cap joint leakage...........................................................................................9
6.3) Line leakage (through seats)...................................................................................9
7. Reparation instructions...............................................................................................9
7.1) Disassembling.........................................................................................................9
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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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 datasheet.
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.
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
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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
3.1 Drawing and Components (Art. 2025V / 2025NV / 2026V / 2027V)

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** Configuration of “V”ball: 30º - 60º or 90º
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.
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.
Part.
Nº
Description
Qty
Material
Spare Part (ref.)
1
Body
1
1.4408
----
2
Cap
2
1.4408
----
3
Ball “V”
1
1.4408
2907V xx xx
(2904X xx xx f/DN100)
4
Stem
1
AISI 316
2905
5
Ball Seat
2
PTFE+FG
2820
6
Gasket
2
PTFE+Graph
2820
7
Thrust Washer
1
PTFE+Graph
2820
8
O-ring
1/2
Viton
2820
9
Packing
1
PTFE
2820
10
Gland
1
AISI 304
----
11
Belleville Washer
2
AISI 301
----
12
Nut
2
AISI 304
----
13
Locking Washer
1
AISI 304
----
14
Stopper
1
AISI 304
----
15
Handle
1
AISI 304
----
16
Washer
1
AISI 304
----
17
Handle Sleeve
1
Plastic
----
18
Screw/Bolt
4/6
AISI 304
----
19
Washer
4/12
AISI 304
----
20
Nut
4/12
AISI 304
----

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4.2) Assembling
- Art. 2025V / 2025NV (threaded ends valve)
Do not disassemble the valves to install them.
Make sure the valve's pipe and thread ends are clean and are compatible one with
another. Apply an appropriate seal in the pipe threads and screw in the valve, being
careful not to tighten too much the conical threads.
Do not use the valve handle as a lever to screw the valve into the pipe.
To tighten the valve, it is recommended to use a spanner or a monkey wrench applying
force only on the hexagonal edges of the valve. It is also recommended this force to be
inferior to 30 Nm.
- Art. 2026V / 2027V (welded ends valve)
a) With the valve in a OPEN position, remove the screws/bolts (part.18), washers
(part.19), nuts (part. 20) and cap (part.2).
b) Turn the ball until reaching the half-open position and remove the seats (part.5) and
gaskets (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) Assemble back the cap (part.2) with the body, keeping them aligned as much as you
can, using only 2 screws (part.18) diagonally opposed. Weld in least 4 different points
(cross-shaped).
d) Remove the body (part.1) from the caps (to avoid welding temperature to damage
PTFE stem washers) and complete the welding process by making sure the caps (part.2)
are protected against welding metal spatters.
e) When cold, clean the cap sealing surface. Place the ball (part.3), seats (part.5) and
gaskets (part.6) on the valve's body and turn the ball into open position.
Place the valve body between the 2 caps being careful not to scratch the contact
surfaces, then place the screws (Part.18) diagonally opposite adjusting until it becomes
subject, place the valve in the closed position and tighten the screws to ensure contact
metal - metal between body and ends (see recommended torques in Section 8.3).

Genebre Building. Av. de Joan Carles I, 46-48
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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
3 pieces full bore ball valves provide a leakproof 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.
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.

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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 3 piece 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:
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 for the valve
every six months.
6.1) Stem leakage
Remove the handle or actuator, the locking washer (part.13) and tighten the nut (part.12)
of the stem packing (see Section 8.2). If the leakage persists, valve should be
disassembled to replace the stem washers (part.7,8,9,10).
See reparation instructions.

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6.2) Body/Cap joint leakage
Check if the body screws (part.18) 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 leakage continues, it is probably due to a damage in the
body gasket 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, leakage 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.
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 an 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,
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 4 / 12 nuts (part.
20) of the screws / bolts (part. 18) that bring
together the three different parts of the valve.
Remove the screws.
Be careful not to damage the cap surfaces.
c.- Remove the central group separating it from
the caps (part. 2).
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 ball could be marked
against the body.
e.- After this, remove the body Gasket (part.6).
They should be removed being carefully not to
scratch or damage the mechanized
surfacesover which they are hermetically sealed.
f.-To disassemble the stem (part. 4), remove the
following elements:
Push the stem inside the body and then remove it. Later, remove the packing (part. 9)
located inside the body. Remove the o’ring (part. 8) from its location and also the thrust
washer (part. 7).
Name
Art. 2025V / 2025NV / 2026V / 2027V
Handle nut
Part.12
Washer
Part.16
Handle
Part.15
Locking washer
Part.13
Nut
Part.12
Spring washers
Part.11
Packing
Part. 9

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g.- Once the valve is disassembled 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 sealing surfaces in the ball, seats, joints and faces 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 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 / o-rings
(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
inside cavity, by pushing a bit to fix it.
b.- Place a new packing (part. 9) from its location in the upper cavity of the body (part.1),
the gland (part. 10) and the spring washers (part. 11) with both external borders together
(concave position). Place the nut (part. 12), tighten it and turn the stem a couple of times.
Then, readjust the nut taking into account the specified torque value (see Section 8.2).
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 insert the lock nut (part. 13) 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) matching the ball slot with stem groove (part. 4). Open the valve so that the ball
does not fall.

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d.- New seats (part. 5) and body gasket (part. 6) can now be placed on both sides of the
body, always keeping flat part of the seat facing outward.
e.- The caps (part. 2) must be clean in their sealing areas before proceeding to final
assembling.
Place the central valve group between the caps and screw the bolts/screws (part. 18) to
bring together the three different parts of the valve.
It is really important that all pieces, such as caps (part. 2), ball (part. 3) and seats (part. 5)
are completely aligned inside.
f.- Then, proceed to place the nuts (part. 12) adjusting slowly and alternating diagonal
until the body becomes subject, place the valve in the closed position and tighten the
screws to ensure contact metal - metal between body and ends (see recommended
torques in Section 8.3).
8. Torque table:
8.1) Breakaway torque:
MEASURE
Breakaway 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
8.2) Torques for the stem nut:
Following numerical data is provided as reference only. Specified torques are the ones
used to operate the assembled stem before assembling ball and seats.

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8.3) Tightening torque Screws/ Nuts for joining the valve's different parts:
Important: The screws must ensure contact metal - metal between body and ends.
These values are appropriate (guidance) by manufacturers of screws / nuts, for our case
has been considered hexagon screws DIN 931/933 and nuts DIN 934 type stainless steel
A2 Class 70:
Valve size
Screw / Nut
Max. torque (N.m.)
1/4" - 3/8” -1/2"
M6
6
3/4" - 1”
M8
15
1 ¼” -1 ½” -2”
M10
30
2 ½” -3” -4”
1/2" W
50
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.
Valve size
Breakaway torque (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

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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.