Jafar 2109 User manual

OPERATION AND MAINTENANCE MANUAL 12-2015
Operation and maintenance
manual for
METAL SEATED
GLAND PACKED
FLANGED
GATE VALVES
P/N
109
909
Approved for use by
President of Factory, JAFAR S.A.
Failure to comply with the guidelines and instructions in this Operation and
Maintenance Manual releases the manufacturer from all obligations, liability and guarantee.
Due to continuous business development, we reserve the right to introduce
modifications and structural changes to the presented product.

OPERATION AND MAINTENANCE MANUAL 12-2015
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CONTENTS
1 TECHNICAL DESCRIPTION ........................................................................................................................... 3
1.1 PRODUCT DESIGNATION AND IDENTIFICATION.............................................................................. 3
1.2 USE............................................................................................................................................................... 3
1.3 TECHNICAL SPECIFICATION.................................................................................................................. 3
2 DESIGN............................................................................................................................................................... 3
2.1 DESCRIPTION OF THE VALVE DESIGN................................................................................................ 3
2.2 MATERIALS................................................................................................................................................ 4
2.3 DIMENSIONS.............................................................................................................................................. 5
2.4 REFERENCE STANDARDS....................................................................................................................... 6
2.5 ORDERING INFORMATION ..................................................................................................................... 7
2.7 MARKINGS ................................................................................................................................................. 7
3 PROTECTION, STORAGE & TRANSPORT.................................................................................................... 7
3.1 PROTECTIVE COATINGS......................................................................................................................... 7
3.2 PACKAGING............................................................................................................................................... 7
3.3 STORAGE.................................................................................................................................................... 8
3.4 TRANSPORT ............................................................................................................................................... 8
4 ASSEMBLY AND INSTALLATION................................................................................................................. 8
4.1 ASSEMBLY GUIDELINES......................................................................................................................... 8
4.2 ASSEMBLY INSTRUCTIONS.................................................................................................................... 9
4.3 OPERATION................................................................................................................................................ 9
4.4 OCCUPATIONAL HEALTH AND SAFETY ............................................................................................. 9
5 WARRANTY TERMS AND CONDITIONS...................................................................................................... 9

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1 TECHNICAL DESCRIPTION
1.1 PRODUCT DESIGNATION AND IDENTIFICATION
The subject of this Operation and Maintenance Manual is:
TYPE 2109 and 2909 metal seated gland packed wedge gate valve
- bore with recess underneath the wedge
- wedge (closure) with metal sealing rings made
of non-ferrous material or stainless steel
- non-rising spindle
- stem sealed with braided gland packing
1.2 USE
The TYPE 2109 and 2909 metal seated braced stem wedge gate valves are intended for industrial
systems, heating systems, air systems for petroleum products and other chemically inert liquids. The valves
are intended for overground and underground installations and must be installed horizontal pipelines in
industrial systems.
1.3 TECHNICAL SPECIFICATION
The metal seated gland packed wedge gate valves with hard seals are intended for transporting of the
specified media and other liquids as agreed with the manufacturer.
- Temperature: -10°C to +150°C
- up to 120°C with bronze rings
- up to 150ºC with steel rings
- Nominal diameter (dimension) range: DN40 to DN600 [mm]
- Maximum medium flow rate: - liquid: max. 4 [m/s]
- gas: max. 30 [m/s]
- The driving torque at opening start and closing end is as listed below:
DN [mm] 40 50 65 80 100 125 150 200 250 300 350 400 500 600
Mmax [Nm]
55 80 100 200 300 400
- Valve control mode: the standard version of gate has the clockwise closing sense of rotation. The
closing sense of rotation can be opposite on special order.
-The valve connection flange design is acc. to PN-EN 1092-2: 1999
with the sizes compliant with the nominal pressure values.
- the connection flanges are manufactured to PN-EN ISO 2285210:2011
- Valve drive coupling type: B3
-- Installation length: PN-EN 558-1: 2012 Series 14.
-
-Nominal pressure PN values: - 1.0 MPa
- 1.6 MPa
2 DESIGN
2.1 DESCRIPTION OF THE VALVE DESIGN
The TYPE 2109 and 2909 metal seated gland packed wedge gate valves manufactured by F.A. JAFAR S.A.
feature a bore with a recess underneath the wedge, a non-rising stem, and an O-ring stem seal installed in the
valve cover. The stem seal is made as a sealing assembly with five (5) braided gland packings. The gate valve
closure is a metallic seals (with rings pressed into the wedge and the valve body seat) with the replaceable spindle

OPERATION AND MAINTENANCE MANUAL 12-2015
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nut on the wedge lug. The top section of the valve cover is the gland packing unit which keeps the flow control
head sealed. The gate valve stem is a cylindrical shaft tipped with a trapezoid thread at the bottom, which is the
drive section, whereas the top tip is designed to match the control element. The valve cover is bolted tight to the
valve body. The valve cover to body seal is an asbestos-free formed gasket. All inner and outer cast-iron surfaces
of the valve are polyvinyl coated. The type 2109 spindle is driven with a hand wheel, and the type 2909 valve is
switched with a drive actuator.
2.2 MATERIALS
The table below lists the structural materials of the metal seated gland packed wedge gate valves with soft
seals.
Item Part designation Material Reference standard
1Body Spheroidal cast-iron, EN-GJS 400-15,
EN-GJS 500-7 PN-EN 1563: 2012
2Cover Spheroidal cast-iron, EN-GJS 400-15,
EN-GJS 500-7 PN-EN 1563: 2012
3Wedge Spheroidal cast-iron, EN-GJS 400-15,
EN-GJS 500-7 PN-EN 1563: 2012
4 Packing gland Spheroidal cast-iron, EN-GJS 400-15,
EN-GJS 500-7 PN-EN 1563: 2012
5 Spindle Steel grade 1.4021 PN-EN 10088-1: 2014
6Gland Spheroidal cast-iron, EN-GJS 400-15,
EN-GJS 500-7 PN-EN 1563: 2012
7 Spindle nut Spheroidal cast-iron, EN-GJS 400-15,
EN-GJS 500-7 PN-EN 1563: 2012
8 Seal Carbon seal, DN40-DN300: PTFE +
carbon; DN350 DN600 acc. to manufacturer's Technical Guidelines
9 O-ring seal Steel grade 1.4021 PN-EN 10088-1: 2014
10 Handwheel Grey cast iron, EN-GJS 250 PN-EN 1561: 2012
11 Valve cover gasket Asbestos-free carbon gasket, DN40-
DN300; AF300 – DN350-DN600 acc. to manufacturer's Technical Guidelines
12 Bolt Steel, 1.0038 – DN40-DN300: Fe/Zn5
– DN350-DN600 PN-EN ISO 4017:2011
13 Nut Steel, 1.0038 – DN40-DN300: Fe/Zn5
– DN350-DN600 PN-EN ISO 4032:2013

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2.3 DIMENSIONS
Drive-ready: 2109 With electric drive actuator: 2909

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DN PN L H H1 d
PN16
(PN10)
D
PN16 (PN10)
K
PN16 (PN10)
C
f
l
PN16 (PN10)
n d1 d2 d3 d4 Dk
LH thread
Drive
No.
of
turn
[mm] [bar]
-
40 140 245 84 150 110 19 3 19 4 160 Tr12X3 15
50 150 255 99 165 125 19 3 19 4 160 Tr12X3 18
65 170 277 118 185 145 19 3 19 4 160 Tr16X4 20
80 180 303 132 200 160 19 3 19 8 160 Tr16X4 26
100 190 340 156 220 180 19 3 19 8 200 Tr20X4 30
125 200 387 184 250 210 19 3 19 8 200 Tr20X4 29
150 210 454 211 285 240 19 3 23 8 200 Tr22X5 36
200 230 538 266 340 295 20 3 23 12 250 Tr22X5 46
250 250 629 319 405 (395) 355 (350) 22 3 28 (23) 12 250 Tr26X5 48
300 270 730 370 460 (445) 410 (400) 25 4 28 (23) 12 320 Tr28X5 57
350 290 860 1033 429 520 (505) 470 (460) 27 4 28 (23) 16 320 Tr32X6 SA 14.2
F14 65
400 310 935 1370 480 580 (565) 525 (515) 28 4 31 (28) 16 320 Tr32X6 74
500 350 1135 1555 609 (582) 715 (670) 650 (620) 32 4 34 (28) 20 630 Tr40X6 91
600 390 1305 1650 720 (682) 840 (780) 770 (725) 36 5 37 (31) 20 630 Tr40X6 108
none
PN10/16
[mm] [mm]
SA 14.6
F14
none none
175 140 30 18 4
2.4 REFERENCE STANDARDS
PN-EN 1074-1: 2002 Valves for water supply. Fitness for purpose requirements and appropriate
verification tests. General requirements
PN-EN 1074-2: 2002 Valves for water supply. Fitness for purpose requirements and appropriate
verification tests. Isolating valves.
PN-EN 1171: 2007 Industrial valves. Cast iron gate valves.
PN-89/H-02650 Valves and pipelines. Pressure and temperature ratings.
PN-EN 1092-2: 1999 Flanges and their joints. Circular flanges for pipes,
valves, fittings and accessories, PN designated. Cast iron flanges.
PN-EN19: 2005 Industrial valves. Marking of metallic valves
PN-EN 12266-1: 2012 Industrial valves. Testing of metallic valves. Pressure tests, test procedures
and acceptance criteria. Mandatory requirements.
PN-EN 558: 2012 Industrial valves. Face-to-face and centre-to-face dimensions of metal valves
for use in flanged pipe systems. PN-designated valves.
PN-EN ISO 6708: 1998 Pipework components. Definition and selection of DN (nominal size).
PN-EN 1559-1: 2011 Founding. Technical conditions of delivery. General.
PN-EN 1561: 2012 Founding. Grey cast irons.
PN-EN 1563: 2012 Founding. Spheroidal graphite cast irons.
PN-EN 1370: 2012 Founding. Surface roughness inspection by
visual tactile comparators.
PN-EN 10088-1: 2014 Stainless steels. List of stainless steels.
PN-74/H-84032 Spring steel. Grades.
PN-EN 1982: 2010 Copper and copper alloys. Ingots and castings.
PN-EN 12420: 2002 Copper and copper alloys. Forgings.
PN-ISO 965-1: 2001 General purpose ISO metric threads. Tolerances. Principles and basic data.
PN-ISO 2903: 1996 Trapezoid ISO metric threads. Tolerances.
PN-EN ISO 4762: 2006 Hexagon socket head cap screws.
PN-EN 10204: 2006 Metallic products. Types of inspection documents.
PN-ISO 1629: 2005 Rubbers and latices. Nomenclature.
PN-EN ISO 1872-1: 2000 Plastics. Polyethylene (PE) moulding and extrusion materials. Designation
system and basis for specifications.
PN-EN ISO 1873-1: 2000 Plastics. Polypropylene (PP) moulding and extrusion materials. Designation
system and basis for specifications.
PN-EN ISO 1874-1: 2010 Plastics. Polyamide (PA) moulding and extrusion materials. Designation
system and basis for specification.
PN-EN ISO 12944-5: 2009 Paints and varnishes. Corrosion protection of steel structures by protective
paint systems. Protective painting systems.

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2.5 ORDERING INFORMATION
Water supply system valves are specific purpose industrial valves, therefore orders must include:
- part number (P/N, equal to the product type);
- intended use, e.g. for water supply systems,
and:
- nominal diameter, acc. to PN-EN ISO 6708: 1998
- nominal pressure, acc. to PN-89/H-02650;
- type of body material — acc. to PN-EN 1561: 2012 or PN-EN 1563: 2012
- maximum operating temperature, acc. to PN-89/H-02650.
2.6 PRODUCTION AND ACCEPTANCE
TYPE 2109 and TYPE 2909 metal seated gland packed gate valves are accepted and produced in
accordance with: PN-EN 1074-2: 2002 (Valves for water supply. Fitness for purpose requirements and
appropriate verification tests. Isolating valves) and PN-EN 12266-1: 2012 (Industrial valves. Testing of valves).
All gate valves are leak tested (100%). The tests include external body tightness and closing tightness.
2.7 MARKINGS
The gate valve marking meets the following standards: PN-EN-19: 2005, PN-EN-1171: 2007.
The gate valve bodies feature markings on the front and back walls of the body chamber. The marking
contains the following data:
- valve type (defined by the product reference standard number)
- nominal diameter
- nominal pressure
- body material type
- manufacturer trademark
The location on the valve specified in the documentation features the nameplate which contains the
following data: - manufacturer's company name and logo
- serial number
- sealing temperature rating
- construction mark "B" and/or mark "CE" (as applicable)
- product type.
3 PROTECTION, STORAGE & TRANSPORT
3.1 PROTECTIVE COATINGS
All inner and outer cast-iron surfaces are protected with grey polyvinyl coat.
The anti-corrosion coating layer minimum thickness is 100µm.
The casting surface is pre-treated for polyvinyl coating in accordance with the relevant technical documentation
and PN-EN ISO 12944-5: 2009.
The screws connecting the body and the cover are manufactured as stainless, grade 1.4301 or Fe/Zn5 (galvanised
steel).
3.2 PACKAGING
The gate valves are packed on EURO pallets (1200x800) and protected with heat-shrunk film.

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3.3 STORAGE
Store the gate valves in sheltered rooms.
3.4 TRANSPORT
Transport the gate valves on sheltered vehicles.
Never suspend the valve by its drive actuator when handling.
It is recommended use belt slings as shown in the diagram above
for handling and installation of the gate valves from DN50 to DN200.
4 ASSEMBLY AND INSTALLATION
4.1 ASSEMBLY GUIDELINES
The Type 2109 and 2909 metal seated gland packed wedge gate valves can be installed in underground
or overground pipelines both in horizontal or vertical orientation. The listed products are suitable for joining with
the flanged ends of pipelines with the size equal to that of the valve flanges. Note that the system must not expose
the (gate) valve to bending or tensile stress from loading with the weight of unsupported pipeline sections.
Assemble with consideration to pressure and temperature compensation of the pipeline. The valve assembled and

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adjusted by the manufacturer is ready for installation. Any dismantling of the valve components may result in loss
of seal.
4.2 ASSEMBLY INSTRUCTIONS
Before attempting to install the valve, check the technical and commercial documents delivered with the
product to verify that the media and pipeline operating parameters comply with the manufacturer's declaration.
Any change in the operating conditions must be consulted with the valve manufacturer beforehand.
Before attempting to assemble the valve, remove the main bore plugs, check the inner surfaces of the
valve and thoroughly flush with water, if necessary.
CAUTION! If the product is damaged mechanically, do not install it in the pipeline.
The figure below shows the method for coupling the gate valve and the valve orientation diagrams:
1. Valve; 2. Nut; 3. Gasket; 4. Pipeline flange; 5. Washer; 6. Fastening bolt
4.3 OPERATION
The gate valve shall be operated according to all relevant requirements for cut-off valves, i.e. either in fully
open or fully closed positions. Leaving the gate valve partially opened (or closed) may result in seal failure. To
ensure full performance, switch the knife gate valve periodically (once a year, from fully open to fully closed).
Exceeding the operating limits of the valve may result in damage that will not covered by the suretyship
granted by the manufacturer.
4.4 OCCUPATIONAL HEALTH AND SAFETY
The metal seated gland packed flanged gate valves are eligible for the OHS guidelines and
recommendation concerning installation of pipelines and devices for water supply stations, heat power plants,
water treatment plants, sewage treatment plants, pumping stations and other facilities, and eligible for the Polish
Regulation concerning general OHS laws (use of personal protective equipment for hands, legs and head, and
safety garment), especially at work with low or high temperature hazard.
Misuse of this product is prohibited.
5 WARRANTY TERMS AND CONDITIONS
Recommend
ed
Permitted
Not permitted

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The product assembled, installed and operated in compliance with this Manual is covered by a
commercial warranty from the manufacturer. The conditions and period of the warranty is specified in the
warranty sheet.