Genebre 2108, 2108A, 2103, 2109 Installation, Operation And Maintenance Manual

Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
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GENEBRE S.A. LAST UPDATE: 08/02/2017 UPDATE NUMBER: 1

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INSTALLATION, OPERATION AND MAINTENANCE

MANUAL

Lug butterfly valve

GENEBRE Reference: 2108 – 2108A

Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
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GENEBRE S.A. LAST UPDATE: 08/02/2017 UPDATE NUMBER: 1

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Installation, operation and maintenance instructions

1) PRODUCT DESCRIPTION ................................................................................................ 3

2) EXPLODED DRAWING ...................................................................................................... 3

2.1) PARTS LIST ................................................................................................................................ ................ 4

3) STORAGE ........................................................................................................................... 4

4) INSTALLATION INSTRUCTIONS ...................................................................................... 4

4.1) PREPARATION ................................................................................................................................ ......... 4

4.2) ASSEMBLING ............................................................................................................................................ 5

5) OPERATION INSTRUCTIONS ........................................................................................... 6

5.1) USAGE ................................ ................................ ................................ ................................ .......................... 6

5.2) MANUAL OPERATION .......................................................................................................................... 6

5.3) REMOTE OPERATION ........................................................................................................................... 7

6) MAINTENANCE OPERATIONS ......................................................................................... 7

7) REPAIR INSTRUCTIONS ................................................................................................... 7

7.1) DISASSEMBLING..................................................................................................................................... 8

7.2) REASSEMBLING ................................ ................................ ................................ ...................................... 8

8) TORQUES ........................................................................................................................... 9

8.1) TORQUES TO ACTIVATE THE VALVES (N.M) .......................................................................... 9

9) HYGIENE AND SAFETY INSTRUCTIONS ......................................................................... 9

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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) Exploded drawing

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2.1) Parts list

N.

Denominación /

Name

Material

Acabado Superficial /

Surface Treatment

Cód. Recambio

Spare Part Code

1

Cuerpo / Body Fundición / Cast Iron EN-GJL-400 Pintado Epoxi / Epoxy Painted

------

2

Disco / Disc Acero Inox. / Stainless Steel 1.4408 (CF8M) Granallado / Shot blasting

------

3*

Elastómero / Seat

EPDM ------ E2109

4

Eje Sup / Upside Stem Acero Inox. / Stainless Steel AISI 416

------ ------

5

Eje Inf / Downside Stem Acero Inox. / Stainless Steel AISI 416

------ ------

6

Casquillo / Bush PTFE + Grafito / Graphite

------ ------

7

Casquillo / Bush PTFE + Grafito / Graphite

------ ------

8

Arandela / Washer Bronce / Bronze

------ ------

9 Seeger DIN 472 ------ ------

10

Tórica / O’ ring

NBR ------ ------

11

Tapón / Plug Acero Carbono / Carbon Steel Cincado / Zinc Plated

------

12

Placa dentada / Plate Acero Carbono / Carbon Steel Cincado / Zinc Plated

------

13→18

Palanca / Handle

Aluminio 2"-6" o Fundición EN-GJL-200 8"-10"

Aluminium 2"-6" or Cast iron EN-GJL-200 8"-10"

Pintado Epoxi / Epoxy Painted

------

19→21

Tornillo+Tuerca+Arandela

Screw+Nut+Washer

Acero / Steel Cincado / Zinc Plated

------

22

Arandela / Washer Acero / Steel Cincado / Zinc Plated

------

23 Tapa / Cover (≥14")

Fundición / Cast Iron EN-GJL-400 Pintado Epoxi / Epoxy Painted

------

24

Tórica / O’ ring (≥14")

NBR ------ ------

25 Tornillo / Screw (≥14")

Acero / Steel Cincado / Zinc Plated

------

3) Storage

Manual valves are provided by default in a half-open position whereas automated valves
usually are in a close 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. The wrap must not be removed until valve
is to be installed. As far as possible, valves must be stored in a dry and clean environment.

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.
Joints between valve and pipe flanges are not necessary, as the elastomer is designed to
keep tightness amongst them.

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

Leave enough space between the flanges
so that valve can be easily inserted or
removed

Fully open the valve before tightening the
screws of the flanges

REMARKS:

- Lug butterfly valves by Genebre, S.A., ref. 2108 are designed to be assembled
between flanges EN 1092 PN16 at a maximum working pressure of 16 bar (until
DN150), and between flanges EN 1092 PN10 at a maximum working pressure of 10
bar (from DN200 and bigger sizes).

- Lug butterfly valves by Genebre, S.A., ref. 2108A, are designed to be assembled
between flanges ANSI 150 (all sizes) at a maximum working pressure of 235 psi (until
12”) and 150 psi (from 14” and bigger sizes).

- Be extremely cautious when placing the valve in the center of the pipe axis to avoid
interferences between disk and inside part of the pipe. The valve must not be
assembled in any case if the internal diameter of the pipe is lower than the nominal
diameter of the valve

- When assembling with a loose flange and a round pipe (or collar) try to avoid the
weld bead to stand out on the inside part of the pipe because this could damage the
disk and even render the valve inoperative

- Verify good parallelism of the flanges

Genebre Building. Av. de Joan Carles I, 46-48
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- Do not install the valve in a completely closed position

- Tighten the screws until the flanges make firm contact with the valve’s body

- When applying it in mud fluid, place the valve in horizontal position (axis being
parallel to the floor) opening the bottom part of the disk in the direction of the flow to
avoid sediment deposits. This installation is strongly recommended for sizes bigger
than DN350 for all kinds of fluid

- Valve must never be assembled adjacent to an elbow in order to avoid turbulences.
Minimum distance recommended between elbow and valve is 3 to 5 times the pipe
diameter

- ATTENTION! If the valve is going to be installed at the end of a pipe, maximum
working pressures will be reduced as following:

DN50 to DN150 … 16 bar x 0.4 = 6,4 bar
DN200 to DN600 … 10 bar x 0.4 = 4 bar

2” to 12” … 235 psi x 0.4 = 94 psi
14” to 24” … 150 psi x 0.4 = 60 psi

5) Operation instructions

5.1) Usage

Valves 2108 / 2108A provide a leakproof seal when used adjusted to the pressure and
temperature values for which they have been designed.
Seat material for the valve, joints, body, disk and axis has to be fully compatible with the fluid
circulating through the valve. Otherwise, valve could be seriously damaged.

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.
Torques required to operate valves are listed in the table Torque to activate the valves, on
page 9.
For the valves operated with gear box (or gear operator), the quantity of turns to be done for
a complete operation cycle of the 90 degree valve will be conditioned by the transmission
ratio of the gear box. See following table:

Genebre Building. Av. de Joan Carles I, 46-48
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Ref. Gear Box Trans. Ratio Nº gear turns (90º)

5975 24:1 6
5976 30:1 7.5
5977 50:1 12.5

5.3) Remote operation

When automation of valves is required, GENEBRE S.A. can provide a great variety of
pneumatic actuators, electric actuators, pneumatic positioners and electropneumatic ones to
cover a large range of operations.

6) Maintenance operations

It is recommended to operate the valve at least once a month.
Elastic-seat butterfly valves are designed so that they do not need any lubrication and/or
periodical maintenance during their life cycle.
However, periodical checks explained below will be useful to extend the service life of the
valve and reduce installation problems:

- Close the valve –from position completely open to completely closed.

- Verify all locks and threaded ends to check if they are loose or with rust. Tighten them if
necessary.

- Inspect the valve and surrounding areas to verify if there is any leakage in the stem or in the
flange connections.

- For an automated valve, verify pipe connections and/or electrical connections of actuators
to check if they are loose due to operation or vibrations.

7) Repair instructions

In case the fluid continues to circulate through the line once the valve is completely closed,
the leakage may be caused by damages in the seat and/or the locking surface, so it will be
necessary to disassemble the valve so that it can be repaired. In this particular case,
GENEBRE, S.A. have different replacement seats or elastomers (part. 3). However, it may
be the case that (for example in an area difficult to access), due to financial reasons, it is not
recommended to repair the valve but directly replace it.

Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
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7.1) Disassembling

You must remove the valve from installation to repair it.

Prepare a clean working area and adequate tools to perform mechanical tasks.

a.- Close the valve. Loosen and extract the screws or bolts from the flanges. Be careful not to
drop the valve. Help yourself with a fastening element if necessary. Place the valve in a valid
clamp.

b.- Remove the lever, the gear operator or the actuator.

c.- Remove the Seeger ring (part. 9) in the upper part with a specific tool and move the upper
axis (part. 4) upwards until it is not in contact with the disk (part. 2) anymore. In this step it
will be necessary to remove all the washers (part. 22) and both halves of the brass ring (part.

8).

d.- Repeat the same operation, but this time with the bottom stem (part. 5) moving it
downwards, previously removing the stub screw (part. 11) located in the bottom part.

e.- Gently bang the disk (part. 2) on its central part with a rubber mallet or similar tool until it
comes off the inside part of the seat (part. 3). Avoid banging the whole perimeter of the disk
because even a small scratch could cause leakage.

f.- To remove the seat (part. 3) we will insert a flat rod between the rubber and the body
acting as a lever.

7.2) Reassembling

Before proceeding to reassemble the valve, make sure that repair kit and/or pieces to be
used are appropriate and original from the factory.
When it is armored again, cleaning is essential for a long life for the valve.

a.- To insert the new seat (part. 3) it is recommended –specially for large sizes– to twist it
with a “8” shape to make the process easier. To spread ordinary grease inside the body will
help. Naturally, both seat holes must fit the central axis of valve’s body.

b.- Place again the disk in its working position and check if it got any damage during
disassembling process.

c.- Place both stems (upper and lower) in their working position and complete the
reassembling by placing the previously removed components in the top stem (part. 8, 9 and

22) and the bottom stem (part. 11).

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08908 L'Hospitalet de Llobregat. Barcelona (Spain)
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d.- Finish off by placing the handle, the reducer gear or the actuator as appropriate, taking
into account their opening or closing position.

e.- Reinstall again the valve between flanges. See Installation instructions on page 5.

8) Torques

8.1) Torques to activate the valves (N.m)

SIZE Max. operational torque

2” 12

2 ½” 20

3” 27
4” 39
5” 58
6” 100

8” 140
10” 240
12” 360
14” 750
16” 900
18” 1200
20” 1700
24” 2500

NOTE: breakaway torque measured after 24h of closing the valve

9) Hygiene and Safety Instructions:

9.1) Fluids that go through the 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.

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9.2) Before removing a valve from a pipe, check always if the line is completely drained and
depressurized.

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.