Genebre 2453, 2453P Installation, Operation And Maintenance Manual

Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
[e-mail] - www.genebre.es

INSTALLATION, OPERATION AND MAINTENANCE

MANUAL

Check valve ball flanges

GENEBRE Reference: 2453 / 2453P

GENEBRE S.A. LAST UPDATE: 23/07/2010 UPDATE NUMBER: 0

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Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
[e-mail] - www.genebre.es

Installation, operation and maintenance instructions

1. Breakdown drawing.............................................................................................................3

1.1) List of components........................................................................................................3

2. Storage................................................................................................................................4

3. Installation instructions ........................................................................................................4

3.1) Preparation...................................................................................................................4

3.2) Assembling...................................................................................................................4

4. Operational instructions.......................................................................................................5

4.1) Usage ...........................................................................................................................5

4.2) Operation......................................................................................................................6

5. Maintenance operations ......................................................................................................6

6.. Reparation instructions.......................................................................................................6

6.1) Disassembling...............................................................................................................6

6.2) Reassembling...............................................................................................................7

7. Pressure for opening ...........................................................................................................7

8. Hygiene and Safety Instructions..........................................................................................7

GENEBRE S.A. LAST UPDATE: 23/07/2010 UPDATE NUMBER: 0

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1) Breakdown drawing.

Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
[e-mail] - www.genebre.es

1.1) List of components

Position Description Quant. Material Finishing

1 BODY 1 GGG-40 Epoxi

Aluminium+NBR (2"-6")

2 BALL 1
3 COVER 1 GGG-40 Epoxi
4 SCREW Depending on size Stainless steel
5 GASKET 1 NBR

Stainless Steel+NBR (8"-10")

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Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
[e-mail] - www.genebre.es

2) Storage

In case valve is not immediately installed, it is recommended to keep it inside the included
protective wrapping to avoid damages or dirt accumulation.The wrap must not be removed
until valve is to be installed. As much as possible, valves must be stored in a dry and clean
environment.

3) Installation instructions

3.1) 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.
Have available some flat gaskets between valve and pipe flanges to keep then tight.
Check correct operation of the valve by pushing the ball (pos.2) in the direction of the flow
and making sure the ball goes back to the original position once it is released. If this is not
the case, check if there are foreign particles inside the valve and repeat the whole operation.
If the ball does not slide smoothly, valve must not be installed.

3.2) Assembling

Check ball valves can only be installed in two different positions:
A.- Horizontal or B.- Vertical (ascendant fluid), as shown in the following sketch:

A.- HORIZONTAL B.- VERTICAL
(COVER UPWARDS) (ASCENDANT FLUID)

GENEBRE S.A. LAST UPDATE: 23/07/2010 UPDATE NUMBER: 0

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Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
[e-mail] - www.genebre.es

IMPORTANT:

- Check ball valve by Genebre, S.A. (art. 2453) is designed to be assembled between
flanges DIN PN16.

- Check ball valve by Genebre, S.A. (art. 2453P) is designed to be assembled
between flanges DIN PN10.

- Be extremely cautious when placing the valve in the center of the pipe axis to keep
tightness between body and flanges.

- Do not weld once the valve is already assembled, as it could be damaged due to
overheating and deformation of the seat area.

- Pay attention to the direction of the valve's flow, indicated with an arrow in the body.

- Verify good parallelism of the flanges. Leave enough space between them so that
valve can be easily inserted or removed.

- Tighten the flanges screws until they make firm contact with the valve’s body. Apply
the alternate tightening method to assure a correct installation.

- Valve must never be assembled adjacent to an elbow, reducer, valve or pump in
order to avoid turbulences. Minimum distance recommended between these elements
is 10 times pipe's diameter -waters up- and 3 times pipe's diameter -waters down­according to CR 13932:2000.

- Never try to install the valve with a different setup than the one indicated in section

3.2.

4) Operational instructions

4.1) Usage

Check valves are mostly used to avoid fluid from going back to the system, by providing a
leakproof lock when used adjusted to the pressure and temperature values for which they
have been designed.
Body material for the valve, ball and rest of components has to be fully compatible with the
fluid circulating through the pipe. Otherwise, valve could be seriously damaged.

GENEBRE S.A. LAST UPDATE: 23/07/2010 UPDATE NUMBER: 0

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Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
[e-mail] - www.genebre.es

4.2) Operation

By default, this type of valve does not need to be operated. Opening and closing are
automated, depending on pressure and direction of the flow. For more information on
opening pressure for the valve, please consult the technical specifications for the product.

5) Maintenance operations

Check valves with soft lock 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:

- Keep the valve in a completely closed position.

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

- Inspect the valve and surrounding areas to verify if there is any leak.

6.) Reparation instructions

In case the fluid continues to circulate through the line once the valve is completely closed,
the leak 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. has replacement balls (pos. 2). However, it may occur 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.

6.1) Disassembling

It is not necessary to remove the valve, but is recommended for a better operation.

Make sure the line is cold, drained and depressurized.
Prepare a clean working area and adequate tools to perform mechanical tasks.

a - Loosen flanges’ setscrews. Be careful not to drop the valve. Help yourself with a fastening
element if necessary. Place the valve in a valid bench screw in ascendant fluid position.

b.- Loosen the screws (pos. 4) and turn the cover (pos. 3) anticlockwise to remove it
completely.
c.- Extract the ball (pos. 2) from inside the valve with your hands. Turn over the valve if
necessary.

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Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
[e-mail] - www.genebre.es

6.2) Reassembling

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

a.- Clean the lock area inside the body (pos. 1).
b.- Insert the ball (pos. 2) into its position.
e.- Place again the cover (pos. 3) in its working position by turning it clockwise and check if

the gasket (pos.5) suffered any damage during disassembling process. Tighten the screws
(pos. 4).

e.- Reinstall the valve between flanges. See Installation instructions on page 4.

7.) Pressure for opening

Check ball valve by GENEBRE, S.A. (art.2453/ art.2453P) has been designed to work with
minimal operational pressures (to obtain more information, please consult the technical
specifications).

8) Hygiene and Safety Instructions

8.1) Fluids that go through the valve can be corrosive, toxic, flammable or pollutant. 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.

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

8.3) Any valve being used by toxic services department needs to obtain a cleanliness

certificate before being operated.

GENEBRE S.A. LAST UPDATE: 23/07/2010 UPDATE NUMBER: 0

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