Genebre 2034 Manuale utente

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: 20/03/2020 UPDATE NUMBER: 2

INSTALLATION, OPERATION AND MAINTENANCE

MANUAL

3 pieces full bore ball valve

with threaded caps and socket weld

GENEBRE Reference: 2034 –2034N –2034S

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: 20/03/2020 UPDATE NUMBER: 2

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...............................................................................................7

5.1) Usage....................................................................................................................7

5.2) Manual operation...................................................................................................7

6. Maintenance instructions ..........................................................................................7

6.1) Stem leaks.............................................................................................................8

6.2) Body/Caps joints leak ............................................................................................8

6.3) Line leaks (through seats)......................................................................................8

7. Reparation instructions .............................................................................................8

7.1) Disassembling .......................................................................................................8

7.2) Reassembling......................................................................................................10

8. Torques table:...........................................................................................................11

9. Hygiene and Safety Instructions:............................................................................12

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: 20/03/2020 UPDATE NUMBER: 2

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 the products have suffered

damages.

Manual valves are provided by default in an 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 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: 20/03/2020 UPDATE NUMBER: 2

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

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: 20/03/2020 UPDATE NUMBER: 2

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.

4.2) Assembling

- Art. 2034 / 2034N (valve with threaded caps)

Do not disassemble the valves for their installation.

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 caps and

thread the valve being careful not to excessively tighten the conical threaded caps.

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 caps, the torque applied being less than 30 Nm.

Part

num.

Description

Quant.

Material

Replacement

(ref.)

Body

WCB

----

Cap

WCB

----

Ball

316

----

Seat

PTFE+FV

2838

Stem

316

----

Joint

PTFE

2838

Screw

A193-B7

----

Friction washer

PTFE

2838

Safety Stopper

304

----

Handle

304

----

Handle cover

Plastic

----

Handle nut

304

----

Washer

304

----

Gland nut

304

----

Wrapping

PTFE

2838

Washer

304

----

Nut

A194-8

----

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: 20/03/2020 UPDATE NUMBER: 2

- Art. 2034S (valve with welding caps)

a) With the valve in OPEN position, remove the screws (part 7), washers (part 16), nuts

(part 17) and the caps (part 2).

b) Turn the ball until reaching the half-open position and remove the seats (part 4) and

joints (part 6) from 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 valve caps (part 2) into the body, keeping them aligned as much as

you can, using only 2 screws (part 7) diagonally opposed. Perform at least 4 welding

points (cross-shaped).

d) Remove the body (part 1) from the valve caps (to avoid welding temperature to

damage rod washers) and complete the welding process by making sure the caps(part 2)

are protected against welding metal spatters.

When cold, clean the caps' locking surfaces. Place the ball (part 3), seats (part 4) and

joints (part 6) on the valve's body and turn the ball into open position.

Place the valve's body between the 2 caps being careful not to scratch the contact

surfaces; then, place the screws (part 7) screwing them diagonally opposed to each other

and respecting the specified torque (see Section 8.3).

IMPORTANT INFORMATION:

Design of this kind of floating ball 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

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

[email protected] - www.genebre.es

GENEBRE S.A.

LAST UPDATE: 20/03/2020 UPDATE NUMBER: 2

5. Operating 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.

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 floating ball 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 caps 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 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.

6. 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.

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.

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: 20/03/2020 UPDATE NUMBER: 2

6.1) Stem leaks

Remove the handle and tighten the gland nut (part 14) of the stem packing (see Section

8.2). If the leak persists, valve should be disassembled to replace the stem washers (part

8,15).

See reparation instructions.

6.2) Body/Caps joints leak

Check if the body screws (part 7) 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 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 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.

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.

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 to the installation system

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: 20/03/2020 UPDATE NUMBER: 2

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 caps when the body is removed.

The stem has two flat part when:

•parallel to pipe → open valve,

•perpendicular to pipe → closed valve,

b.- Loosen and remove the 4 / 6 nuts (part

17) of the screws / studs (part 7) that bring

together the three different parts of the

valve. Remove the screws.

Be careful not to damage the caps

surfaces.

c.- Remove the central group separating it

from the stoppers (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 4). 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 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.

b.- To disassemble the stem, loosen and remove the nut

(part 12), remove the washer (part 13) and the handle

(part 10). Loosen and remove the gland nut (part 14) and

push the stem (part 5) towards the inside part of the body

and remove it. Later, remove the packaging (part 15)

located inside the body. a.- Place a new friction washer

(part 8).

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: 20/03/2020 UPDATE NUMBER: 2

g.- Once the valve is disassembled you must verify the state of each single piece that

composes 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 caps 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 providing it with a long life.

a.- Place a new friction washer (part 8) on the stem (part 5) 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 15) into its location in the upper cavity of the body (part

1). Place the gland nut (part 1214) and tighten it. Make the stem turn a couple of times

and readjust the nut, respecting the torque specified 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.

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

cavity (part 1) matching the ball slot with stem milling (part 5). Open the valve so that the

ball does not fall.

d.- New seats (part 4) 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 2) need to have locking parts cleaned before proceeding to

final assembly.

Questo manuale è adatto per i seguenti modelli

Indice

Altri manuali Genebre Unità di controllo

Manuali Unità di controllo popolari di altre marche

Festo

Festo Compact Performance CP-FB6-E Manuale elenco delle parti

Elo TouchSystems

Elo TouchSystems DMS-SA19P-EXTME Manuale utente

JS Automation

JS Automation MPC3034A Manuale utente

JAUDT

JAUDT SW GII 6406 Series Guida rapida

Spektrum

Spektrum Air Module System Manuale utente

BOC Edwards

BOC Edwards Q Series Manuale utente

KHADAS

KHADAS BT Magic Manuale utente

Etherma

Etherma eNEXHO-IL Manuale utente

PMFoundations

PMFoundations Attenuverter Manuale utente

GEA

GEA VARIVENT Manuale utente

Walther Systemtechnik

Walther Systemtechnik VMS-05 Manuale utente

Altronix

Altronix LINQ8PD Istruzioni per il montaggio

Eaton

Eaton Powerware Series Manuale utente

WAGO

WAGO 750-407/040-000 Manuale utente

Sony

Sony CCU-590 Manuale utente

Graco

Graco 25D614 Manuale utente

Task Force Tips

Task Force Tips YE-RF-900 Manuale di programmazione

Shini

Shini SPV-U Series Manuale utente