Genebre 2040 Bedienungsanleitung

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

LAST UPDATE: 17/08/2021 UPDATE NUMBER: 5

INSTALLATION, OPERATION AND MAINTENANCE

MANUAL

3 way ball valve "L" and "T" bore

threaded and flanged ends

Ref. GENEBRE: 2040–2040N–2041–2041N

2540–2541–2540E–2541E

2544–2545

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

LAST UPDATE: 17/08/2021 UPDATE NUMBER: 5

Installation, operation and maintenance instructions

1. Product description.....................................................................................................3

2. Transport and Storage conditions .............................................................................3

3. Valve breakdown..........................................................................................................4

3.1 Drawing and Components (Art. 2040 / 2041).........................................................................4

3.2 Drawing and Components (Art. 2540 / 2541).........................................................................5

3.3 Drawing and Components (Art. 2540E / 2541E / 2544 / 2545)..............................................7

4. Installation instructions ..............................................................................................8

4.1) Preparation .............................................................................................................................8

4.2) Assembling.............................................................................................................................8

5. Operating instructions ................................................................................................9

5.1) Usage......................................................................................................................................9

5.2) Manual operation....................................................................................................................9

6. Maintenance instructions..........................................................................................10

6.1) Stem leaks ............................................................................................................................10

6.2) Body/Cap gasket leakage .....................................................................................................10

6.3) Leakage in the line (through seats). .....................................................................................11

7. Reparation instructions.............................................................................................11

7.1) Disassembling ......................................................................................................................11

7.2) Reassembling .......................................................................................................................13

8. Torque table:..............................................................................................................15

9. Hygiene and Safety Instructions:.............................................................................16

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

LAST UPDATE: 17/08/2021 UPDATE NUMBER: 5

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.

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.

During storage it is recommended to keep them into 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.

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

LAST UPDATE: 17/08/2021 UPDATE NUMBER: 5

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. Valve breakdown

3.1 Drawing and Components (Art. 2040 / 2041)

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

LAST UPDATE: 17/08/2021 UPDATE NUMBER: 5

Nº

Denominación / Name

Material

Acabado Superficial/

Surface Treatment

Cód. Recambio

Spare Part Code

Cuerpo / Body

Acero Inox. / Stainless Steel 1.4408

Granallado + Decapado /

Shot blasting + Pickling

------

Tapa / Cap

Acero Inox. / Stainless Steel 1.4408

Granallado + Decapado /

Shot blasting + Pickling

------

Bola / Ball

Acero Inox. / Stainless Steel 1.4408

------

2840 "L" // 2841 "T"

Asiento / Ball Seat

Teflón + 15% FV / PTFE + 15% FG

------

2819

Eje / Stem

Acero Inox AISI 316 / SS 316

------

Dispositivo Anti-estático /

Anti-Static device

Acero Inox AISI 316 / SS 316

------

Anillo Fricción / Thrust Washer

PTFE

------

2819

Tórica / O’ ring

FKM ( Viton)

------

2819

Empaquetadura / Stem packing

PTFE

------

2819

Guarnición / Bushing

Inox. + PTFE / S.S. + PTFE

------

Anillo Prensa / Gland

Acero Inox AISI 304 / SS 304

------

Arandela Resorte / Spring Washer

Acero Inox AISI 301 / SS 301

------

Tuerca / Nut

ASTM A194-8

------

Antigiro / Nut Locker

Acero Inox AISI 304 / SS 304

------

Arandela / Washer

Acero Inox AISI 304 / SS 304

------

Tuerca Maneta / Handle Nut

Acero Inox AISI 304 / SS 304

------

Funda / Handle Sleeve

Vynil

------

Maneta / Handle

Acero Inox AISI 304 / SS 304

------

Bloqueo maneta / Lock device

Acero Inox AISI 304 / SS 304

------

20*

Junta / Gasket

PTFE

------

2819

Tornillo Tope / Stop Bolt

Acero Inox AISI 304 / SS 304

------

Tuerca / Nut

ASTM A194-8

------

* Available spare parts

3.2 Drawing and Components (Art. 2540 / 2541)

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

LAST UPDATE: 17/08/2021 UPDATE NUMBER: 5

Nº

Denominación / Name

Material

Acabado Superficial /

Surface Treatment

Cód. Recambio

Spare Part Code

Cuerpo / Body

Acero Inox. / SS 1.4408

Granallado / Shot blasting

------

Tapa / Cap

Acero Inox. / SS 1.4408

Granallado / Shot blasting

------

Bola / Ball

Acero Inox. / SS 1.4408

------

B2540 "L" / B2541 "T"

Asiento / Ball Seat

PTFE + 15% FV / GF

------

2928

Eje / Stem

Acero Inox. / SS AISI 316

------

Anillo Fricción / Thrust washer

PTFE

------

2928

Tórica / O’ ring

FPM (Viton)

------

2928

Empaquetadura / Stem packing

PTFE

------

2928

Casquillo / Bushing

Inox. + PTFE / S.S. + PTFE

------

2928

Anillo Prensa / Gland

Acero Inox / SS AISI 304

------

Arandela Resorte / Spring Washer

Acero Inox / SS AISI 304

------

Tuerca vástago / Stem Nut

Acero Inox / SS AISI 304

------

Antigiro / Nut Locker

Acero Inox / SS AISI 304

------

Arandela / Washer

Acero Inox / SS AISI 304

------

Maneta / Handle (DN25-DN50)

Acero Inox / SS AISI 304

------

Tapa ciega / End Cap

Acero Inox. / SS 1.4408

Granallado / Shot blasting

------

Bloqueo maneta / Lock device (DN25-DN50)

Acero Inox / SS AISI 304

------

18*

Junta / Gasket

PTFE

------

2928

Tornillo / Bolt

Acero Inox / SS AISI 304

------

Funda / Handle Sleeve

Vynil

------

Tornillo Tope / Stop Bolt

Acero Inox / SS AISI 304

------

Tuerca / Nut

Acero Inox / SS AISI 304

------

Adaptador Maneta / Handle Adapter

(DN65-DN100)

Acero Inox / SS AISI 304

Granallado / Shot blasting

------

Tornillo / Bolt

Acero Inox / SS AISI 304

------

Maneta / Handle

ASTM A 53

Cincado / Zn Plated

------

Funda / Handle Sleeve

Vynil

------

Tapa Inferior / Bottom Cap

Acero Inox / SS AISI 316

Granallado / Shot blasting

------

28*

Junta / Gasket

PTFE

------

2928

Tornillo / Bolt

Acero Inox / SS AISI 304

------

30*

Casquillo / Bush

PTFE

------

2928

31*

Disco / Disk

PTFE

------

2928

*Available spare parts

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

LAST UPDATE: 17/08/2021 UPDATE NUMBER: 5

3.3 Drawing and Components (Art. 2540E / 2541E / 2544 / 2545)

Nº

Denominación / Name

Material

Acabado Superficial /

Surface Treatment

Recambios /

Spare Parts

2540E / 2541E

2544 / 2545

Cuerpo / Body

Acero Inox. / SS 1.4408

Acero / Steel 1.0619

Granallado / Shot blasting

------

Tapa / Cap

Acero Inox. / SS 1.4408

Acero / Steel 1.0619

Granallado / Shot blasting

------

Bola / Ball

Acero Inox. / Stainless Steel 1.4408

------

B2544 “L” /

B2545 “T”

Asiento / Ball Seat

PTFE + 15% F.V. / PTFE + 15% G.F.

------

K2544

Eje / Stem

Acero Inox. / Stainless Steel AISI 316

------

Anillo Fricción / Thrust washer

PTFE

------

K2544

Tórica / O’ ring

FPM

------

K2544

Empaquetadura / Stem packing

PTFE

------

K2544

Dispositivo antiestático /

Antistatic device

Acero Inox. / Stainless Steel AISI 316

------

Anillo Prensa / Gland

Acero Inox. / Stainless Steel AISI 304

------

Arandela Resorte / Spring Washer

Acero Inox. / Stainless Steel AISI 301

------

Tuerca vástago / Stem Nut

Acero Inox. / Stainless Steel AISI 304

------

Antigiro / Nut Locker

Acero Inox. / Stainless Steel AISI 304

------

Arandela / Washer

Acero Inox. / Stainless Steel AISI 304

------

Maneta / Handle (DN25-DN50)

Acero Inox. / Stainless Steel AISI 304

------

Prisionero / Set Screw (DN65-DN100)

Acero Inox. / Stainless Steel AISI 304

------

Bloqueo maneta / Lock device (DN25-DN50)

Acero Inox. / Stainless Steel AISI 304

------

18*

Junta / Gasket

PTFE

------

K2544

Tornillo / Bolt

Acero Inox. / Stainless Steel AISI 304

------

Funda / Handle Sleeve (DN25-DN50)

Vynil

------

Tornillo Tope / Stop Bolt

Acero Inox. / Stainless Steel AISI 304

------

Tuerca / Nut

Acero Inox. / Stainless Steel AISI 304

------

Adaptador Maneta / Handle Adapter (DN65-DN100)

Acero Inox. / Stainless Steel 1.4308

Granallado / Shot blasting

------

Tornillo / Bolt (DN65-DN100)

Acero Inox. / Stainless Steel AISI 304

------

Maneta / Handle (DN65-DN100)

Acero Inox. / Stainless Steel AISI 304

------

Funda / Handle Sleeve (DN65-DN100)

Vynil

------

Tapa Inferior / Bottom Cap (DN65-DN100)

Acero Inox. / SS 1.4408

Acero / Steel 1.0619

------

28*

Junta / Gasket (DN65-DN100)

PTFE

------

K2544

Tornillo / Bolt (DN65-DN100)

Acero Inox. / Stainless Steel AISI 304

------

30*

Casquillo / Bush (DN65-DN100)

PTFE

------

K2544

31*

Disco / Disk (DN65-DN100)

PTFE

------

K2544

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

LAST UPDATE: 17/08/2021 UPDATE NUMBER: 5

*Available spare parts

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

- Art. 2040 / 2041 (valve with threaded ends)

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 ends and

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

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.

- 2540 (E) / 2541 (E) / 2544 / 2545 (valve with threaded ends)

Do not disassemble the valves for their installation.

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 situated.

After assembling, check the tightness and performance of the valve.

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

LAST UPDATE: 17/08/2021 UPDATE NUMBER: 5

IMPORTANT INFORMATION:

The design of this type of 3-way ball valves with four seats allows us to install

them in any position as the fluid entrance can be any of the three.

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 pipes to extend lifecycle of the valve.

5. Operating instructions

5.1) Usage

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.

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.

In case you need to remove the handle to automate the valve, the stem (part 5) has a

mechanized linear mark at the front part (“L”or “T”shape) that allows us to know its

current position.

Genebre Building. Av. de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)

genebre@genebre.es - www.genebre.es

GENEBRE S.A.

LAST UPDATE: 17/08/2021 UPDATE NUMBER: 5

5.3) Remote operation

When automation of the 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.

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.

Valves must not remain in the same 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.

6.1) Stem leaks

Remove the handle or actuator, the lock nut washer (part 14-Threaded / part 1-Flanged)

and tighten the nut (part 13-Threaded / part 12 Flanged) of the stem packing (see Section

8.2). If the leakage persists, valve should be disassembled to replace the stem washers

(parts 7,8,9,10-Threaded / parts 6, 7, 8, 9-Flanged).

See reparation instructions.

6.2) Body/Cap gasket leakage

- Art. 2040 / 2041 (valve with threaded ends)

Check if the caps (part 2) is tight. If it was loose, tighten it. 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.

- Art. 2540 (E) / 2541 (E) / 2544 / 2545 (valve with flanged ends)

Check if the body screws (part 21) 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 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.

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