Jafar 2502 User manual

OPERATION AND MAINTENANCE MANUAL 12-2016
Operation and maintenance
manual for
GATE VALVES
WITH SOFT SEALS
AND OPENING INDICATO
P/N
2502; 2511
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 12-2016
2
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 ..................................................................................................................... 6
2.6 PRODUCTION AND ACCEPTANCE ........................................................................................................ 6
2.7 MARKINGS ................................................................................................................................................. 7
3 PROTECTION, STORAGE & TRANSPORT.................................................................................................... 7
3.1 PROTECTIVE COATINGS......................................................................................................................... 7
3.2 PACKAGING............................................................................................................................................... 7
3.3 STORAGE.................................................................................................................................................... 7
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 2502 and 2511 gate valves with soft seals and opening indicator:
- full smooth walled bore design
- wedge (closure) embedded in 100% pure elastomer
- non-rising spindle
- stem head-type seal in valve cover (O-rings)
- with the valve closure position indicator
1.2 USE
The Type 2502 and 2511 gate valves with soft seals and opening indicator are intended for water
supply systems and industrial processing systems. The valves are intended for horizontal pipelines in
industrial systems.
1.3 TECHNICAL SPECIFICATION
The Type 2502 and 2511 gate valves with soft seals and position indicator are applied in transfer of
potable water, process water and other liquids as approved by the manufacturer.
- temperature range: -10°C to +70°C
- Nominal diameter (dimension) range: DN40 to DN300 [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
Mmax [Nm]
55 80 100 200
Valve control mode: the standard version of gate valve has the
clockwise closing sense of rotation.
The closing sense of rotation can be opposite on special order.
- Installation length: EN 558-1 Series 14 - TYPE 2511
- Series 15 - TYPE 2502
- The valve connection flange design is acc. to EN 1092-2
with the sizes compliant with the nominal pressure values.
- 0.6 MPa
- 1.0 MPa
- 1.6 MPa
2 DESIGN
2.1 DESCRIPTION OF THE VALVE DESIGN
Type 2502 and 2511 gate valves with soft seals and position indicator manufactured by F.A. JAFAR S.A.
feature a smooth walled bore, a non-ring spindle atop of which is the valve closure position indicator installed,
and an o-ring spindle seal installed in a head-type valve cover. The stem is guided by a bushing in the valve cover
neck and a sealing plug. The spindle seal is effected by the plug sealing assembly, which is a system of O-rings.
The gate valve closure is a cast iron wedge completely coated with rubber and featuring a stem nut located on the
wedge lug. The stem is equipped with an interlocking collar installed by necking. From the bottom the stem
collar rests on a seat in the head via a bushing which acts as a sealed bearing. The plug is secured against
loosening with a wire spring ring located over the plug flange. The valve cover to body joint is made with

OPERATION AND MAINTENANCE MANUAL 12-2016
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hexagon socket head cap screws mounted flush with the valve cover and secured with paraffin compound. The
fastening bolts are either galvanized steel or stainless steel. The valve cover to body seal is a rubber gasket which
also seals the bolt penetration points to prevent any leaks from their leads. All inner and outer cast-iron surfaces
of the valve are epoxy powder coated. The spindle is driven by a hand wheel.
2.2 MATERIALS
The table below lists the structural materials of the gate valves with soft seals.
Item Part designation Material Reference standard
1Body Cast-iron, EN-GJS-400-15
EN-GJS-500-7 EN 1563
2 Cover Cast-iron, EN-GJS-400-15
EN-GJS-500-7 EN 1563
3 Wedge Cast-iron, EN-GJS-400-15 EN-GJS-500-7
Rubber, EPDM/NBR
EN 1563
EN 1629
4 Skid Polyamide EN ISO 1874-1
5 Spindle Steel grade 1.4057 / 1.4021 EN 10088
6 Link Grey cast-iron, EN-GJL-250
Polyethylene EN 1561 EN ISO 1872-1
7 Pointer Brass
Polyethylene EN 1982 EN ISO 1872-1
8Indicator dial Steel grade 1.4021 EN10088-1
9Sealing plug Bronze, copper EN 1982
10 Spindle nut Bronze, copper EN 1982
11 Valve cover gasket Rubber: EPDM/NBR ISO 1629
12 O-ring Rubber: EPDM/NBR ISO 1629
13 O-ring Rubber: EPDM/NBR ISO 1629
14 Bolt Steel, Fe/Zn5, stainless steel EN ISO 4762
15 Bolt plug Paraffin acc. to manufacturer's Technical
Guidelines
16 Washer Polyamide PA6 EN ISO 1874-1
17 Nut Steel, Fe/Zn5, or stainless steel EN ISO 4032
18 Set screw Stainless steel EN ISO 4027
19 Hand wheel Grey cast-iron, EN-GJL-250 EN 1561

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2.3 DIMENSIONS
Diagram of the gate valve with soft seals and opening indicator.
- 2511 [kg] 2502 [kg]
40 140 240 290 84 150 110 19 19 3 4 200 14 11 12
50 150 250 315 99 165 125 19 19 3 4 200 14 13 14
65 170 270 345 118 185 145 19 19 3 4 200 17 18 19
80 180 280 385 132 200 160 19 19 3 8 200 17 21 23
100 190 300 435 156 220 180 19 19 3 8 250 19 30 33
125 200 325 475 184 250 210 19 19 3 8 250 19 36 42
150 210 350 535 211 285 240 23 19 3 8 250 19 50 54
200 230 400 620 266 340 295 23 20 3 12 (8) 320 24 70 87
250 250 450 720 319 405 355 (350) 28 (23) 22 3 12 320 27 98 112
300 270 500 830 370 460 410 (400) 28 (23) 25 4 12 320 27 132 159
Mass
2502
L
K
PN16 (PN10)
C
Mass
Sf
[mm]
DN 2511
LDk
[mm]
d
PN16 (PN10)
l
PN16 (PN10)
n
PN16 (PN10)
DH

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2.4 REFERENCE STANDARDS
EN 1074-1 Valves for water supply. Fitness for purpose requirements and appropriate
verification tests. General requirements
EN 1074-2 Valves for water supply. Fitness for purpose requirements and appropriate
verification tests. Isolating valves.
89/H-02650 Valves and pipelines. Pressure and temperature ratings.
EN 1092-2 Flanges and their joints. Circular flanges for pipes,
valves, fittings and accessories, PN designated. Cast iron flanges.
EN19 Industrial valves. Marking of metallic valves
EN 12266-1 Industrial valves. Testing of metallic valves. Pressure tests, test procedures
and acceptance criteria. Mandatory requirements.
EN 558 Industrial valves. Face-to-face and centre-to-face dimensions of metal valves
for use in flanged pipe systems. PN-designated valves.
EN ISO 6708 Pipework components. Definition and selection of DN (nominal size).
EN 1559-1 Founding. Technical conditions of delivery. General.
EN 1561 Founding. Grey cast irons.
EN 1563 Founding. Spheroidal graphite cast irons.
EN 1370 Founding. Surface roughness inspection by
visual tactile comparators.
EN 10088-1 Stainless steels. List of stainless steels.
74/H-84032 Spring steel. Grades.
EN 1982 Copper and copper alloys. Ingots and castings.
EN 12420 Copper and copper alloys. Forgings.
EN ISO 4032 Hexagon regular nuts (style 1). Product grades A and B.
ISO 965-1 General purpose ISO metric threads. Tolerances. Principles and basic data.
ISO 2903 Trapezoid ISO metric threads. Tolerances.
EN ISO 4762 Hexagon socket head cap screws.
EN ISO 4027 Hexagon socket set screws with cone point.
EN 10204 Metallic products. Types of inspection documents.
ISO 1629 Rubbers and latices. Nomenclature.
EN ISO 1873-1 Plastics. Polypropylene (PP) moulding and extrusion materials. Designation
system and basis for specifications.
EN ISO 1874-1 Plastics. Polyamide (PA) moulding and extrusion materials. Designation
system and basis for specification.
EN ISO 12944-5 Paints and varnishes. Corrosion protection of steel structures by protective
paint systems. Protective painting systems.
2.5 ORDERING INFORMATION
Water supply system fittings are specific purpose industrial fittings, therefore orders must include:
- Part Number (P/N)
- intended use, e.g. for water supply systems, sea water, etc.
and:
- nominal diameter, acc. to EN ISO 6708
- nominal pressure, acc. to 89/H-02650;
- type of body material — acc. to EN 1561; EN 1563
- maximum operating temperature, acc. to 89/H-02650.
2.6 PRODUCTION AND ACCEPTANCE
Type 2502 and 2511 gate valves with soft seals and opening indicator are accepted and produced in
accordance with EN 1074-2 (Valves for water supply. Fitness for purpose requirements and appropriate
verification tests. Isolating valves) and EN 12266-1 (Industrial valves. Testing of valves). All gate valves are leak
tested (100%). The tests include external body tightness and closing tightness.

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2.7 MARKINGS
The gate valve marking meets the following standards: EN-19; EN-1074-1.
The 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 electro-deposited epoxy coat. The coat has been
approved for contact with foodstuffs.
The anti-corrosion coating layer minimum thickness is 250µm.
The screws connecting the body and the cover are manufactured as stainless, grade OH18N9 or Fe/Zn5
(galvanised steel).
3.2 PACKAGING
The gate valves are packed on EURO pallets (1200x800) and protected with heat-shrunk film.
3.3 STORAGE
Store the gate valves in sheltered rooms.

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3.4 TRANSPORT
Transport the gate valves on sheltered vehicles.
It is recommended to handle and assemble the DN80 to DN300 gate valves with belt slings as shown in the
diagram above.
4 ASSEMBLY AND INSTALLATION
4.1 ASSEMBLY GUIDELINES
The TYPE 2502 and TYPE 2511 gate valves with soft seals and position indicator can be installed in
surface 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 adjusted
by the manufacturer is ready for installation. Any dismantling of the valve components may result in loss of seal.

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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 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
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.
Recommended
Not permitted
Permitted