Jafar 2901 User manual

OPERATION AND MAINTENANCE MANUAL 09-2015
Operation
and Maintenance Manual
FLANGE-TO-FLANGE
GATE VALVES
WITH SOFT SEALS
AND PNEUMATI A TUATORS
P/N
2901
2903
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 warranty.
Due to the continuous development of the company, we reserve the right to
modifications and design changes in the product presented herein.

OPERATION AND MAINTENANCE MANUAL 09-2015
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CONTENTS
1 TECHNICAL DESCRIPTION............................................................................................................................ 3
1.1 PRODUCT DESIGNATION AND IDENTIFICATION.............................................................................. 3
1.2 USE............................................................................................................................................................... 3
1.3 TECHNICAL CHARACTERISTICS........................................................................................................... 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 MARKING.................................................................................................................................................... 6
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 GENERAL.................................................................................................................................................. 10
4.5 OCCUPATIONAL HEALTH AND SAFETY ........................................................................................... 10
5 WARRANTY TERMS AND CONDITIONS.................................................................................................... 10

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1 TECHNICAL DESCRIPTION
1.1 PRODUCT DESIGNATION AND IDENTIFICATION
The subject of this Operation and Maintenance Manual is:
Type 2901 and 2903 flange-to-flange wedge gate valves with soft seals and a pneumatic linear actuator.
- full smooth walled bore design
- wedge (closure) embedded in 100% pure elastomer
- rising spindle
- spindle head-type seal in valve cover (O-rings)
1.2 USE
The Type 2901 and 2903 cast iron flange-to-flange wedge gate valves with soft seals are intended for water
supply systems, especially for potable water, sewage systems, and industrial processing systems. The valves are
intended for overground and underground (vaulted) systems and must be installed in horizontal pipelines.
1.3 TECHNICAL CHARACTERISTICS
The Type 2901 and 2903 flange-to-flange wedge gate valves with soft seals and a pneumatic linear
actuator are applied in transfer of potable water, process water and other liquids as approved by the
manufacturer.
- Operating temperature range: +70°C max.
- Nominal diameter (dimension) range: DN40 to DN400 [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
Mmax [Nm]
25 50 100 200 250 280
- Valve control mode: pneumatic actuator.
- The valve connection flange design is acc. to PN-EN 1092-2: 1999
with the sizes compliant with the nominal pressure values.
- Special flanged connection for the pneumatic actuator.
- Installation length: PN-EN 558-1: 2012 series 14 - Type 2901
series 15 - Type 2903
- Nominal pressure ratings (PN): - 0.6 MPa
- 1.0 MPa
- 1.6 MPa
2 DESIGN
2.1 DESCRIPTION OF THE VALVE DESIGN
Type 2901 and 2903 flange-to-flange wedge gate valves with soft seals and a pneumatic linear actuator
manufactured by F.A. „JAFAR” S.A. feature a smooth walled bore, a rising spindle, and an o-ring spindle seal
installed in a head-type valve cover. The spindle 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 spindle nut located on the wedge lug
and linked with the pneumatic actuator piston. The top part of the sealing plug is secured against loosening with a
wire spring ring. The valve cover to body joints is made with hex cap screws mounted flush with the valve cover
and preserved with a paraffin compound.

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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 gate
valves from DN350 to DN400 feature a wedge guide system made of plastic inserts.
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
or EN-GJS-500-7 PN-EN 1563: 2012
2Cover Cast iron, EN-GJS-400-15
or EN-GJS-500-7 PN-EN 1563: 2012
3 Link Cast iron, EN-GJS-400-15
or EN-GJS-500-7 PN-EN 1563: 2012
4Sealing plug Brass PN-EN 1982: 2010
5Safety ring Steel grade 1.1260 PN-74/H-84032
6Wedge Cast iron, EN-GJS-400-15 or EN-GJS-500-7
EPDM/NBR
PN-EN 1563: 2012
PN-EN 1563: 2012
PN-ISO 1629: 2005
7Spindle nut Brass
or EN-GJS-400-15 PN-EN 1982: 2010 PN-EN 1563: 2012
8Spindle Steel grade 1.4021 PN-EN 10088-1: 2014
9Valve cover gasket EPDM/NBR PN-ISO 1629: 2005
10
11 O-ring EPDM/NBR PN-ISO 1629: 2005
12 Bolt Steel, Fe/Zn5, stainless steel PN-EN ISO 4762: 2006
13 Pneumatic actuator Manufacturer's catalogue

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2.3 DIMENSIONS
DN 2901
L2903 LH1 H d D
K
PN16 (PN10)
I
PN16 (PN10) C f
n
PN16 (PN10) Actuator type
- -
40 140 240 219 417 84 150 110 19 19 3 4 18.2696.0060AK
50 150 250 229 437 99 165 125 19 19 3 4 18.2696.0070AK
65 170 270 257 475 118 185 145 19 19 3 4 18.2696.0080AK
80 180 280 282 520 132 200 160 19 19 3 8 18.2696.0100.AK
100 190 300 319 599 156 220 180 19 19 3 8 18.2680.0120.AK
125 200 325 358 658 184 250 210 19 19 3 8 18.2680.0140.AK
150 210 350 434 784 211 285 240 23 19 3 8 18.2681.0170.AK
200 230 400 509 909 266 340 295 23 20 3 12 (8) 18.2681.0220.AK
250 250 450 603 1053 319 405 355 (350) 28 (23) 22 3 12 18.2719.0270.AK
300 270 500 678 1178 370 460 410 (400) 28 (23) 25 4 12 18.2719.0320.AK
350 290 550 827 1437 429 520 470 (460) 28 (23) 27 4 16 18.2724.0400.AK
400 310 600 1060 1730 480 580 525 (515) 31 (28) 28 4 16 18.2724.0450.AK
[mm]

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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-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 length in metal straight and angle fittings for
flange pipelines. Fittings with PN and class markings.
PN-EN ISO 5210: 2011 Industrial valves. Multi-turn valve actuator attachments.
PN-EN ISO 6708: 1998 Pipework components. Definition and selection of DN (nominal size).
PN-EN 1559-1: 2011 Foundry. Technical conditions for delivery. Delivery specifications.
PN-EN 1561: 2012 Founding. Grey cast irons.
PN-EN 1563: 2012 Founding. Spheroidal graphite cast irons.
PN-EN 1370: 2012 Foundry. Surface roughness testing using
visual and tactile reference.
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 Metal products. Types of control documents.
PN-ISO 1629: 2005 Rubbers and latices. Nomenclature.
PN-EN ISO 1873-1: 2000 Plastics. Polypropylene (PP) injection and extrusion moulding materials.
Marking system and basis for classification.
PN-EN ISO 1874-1: 2010 Plastics. Polyamide (PA) moulding and extrusion materials. Marking and
basis for classification.
PN-EN ISO 12944-5: 2009 Paints and varnishes. Corrosion protection of steel structures by protective
paint systems. Protective paint systems.
2.5 ORDERING INFORMATION
Water supply system fittings are specific purpose industrial fittings, 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 2901 and 2903 gate valves with soft seals are accepted and produced in accordance with PN-EN
1074-2: 2002 (Valves for water supply. Fitness for purpose requirements and appropriate verification tests. Stop
fittings) 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 MARKING

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The gate valve marking meets the following standards: PN-EN-19: 2005, PN-EN-1074-1: 2002. 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 grade
- the Polish Building Mark "B" and/or the CE mark (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 250 µm. The casting surface is pre-treated for epoxy
coating in accordance with the relevant technical documentation and PN-EN ISO 12944-5:2009. The cover-to-
body fastening bolts are 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. Heavy gate valves (DN350 and larger) shall be handled
with the integrated handling pieces made of eye bolts; the gate valves from DN40 to DN300 shall be handled on
slings. Never suspend the valve by its pneumatic actuator when handling.
4 ASSEMBLY AND INSTALLATION
4.1 ASSEMBLY GUIDELINES
Type 2901 and 2903 flange-to-flange wedge gate valves with soft seals and a pneumatic linear actuator
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 valve to bending or tensile stress from loading with the unsupported
pipeline sections.
It is recommended to perform installation works considering pipeline compensation due to temperature
and pressure. The valve assembled and adjusted by the manufacturer is ready for installation. Any dismantling of
the valve components may result in loss of seal. When installing the gate valve with its actuator, follow the OHS
requirements specified in the actuator operation and maintenance manuals.

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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 mechanical damage is found on the product, do not install it in the pipeline.
Before commissioning the gate valve equipped with an actuator, check during the connection
and adjustment of the actuator that the
joints of the air supply system and electrocution protection features have been installed
according to the manual from the actuator manufacturer.
The figure below shows the method for coupling the gate valve with its pneumatic actuator 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 knife 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.
Recommend
ed
Permitted
Not permitted

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4.4 GENERAL
This Manual applies to all Group 2000 products designed for equipping with actuators (i.e. gate valves
of various connection end types) and manufactured by FA. JAFAR S.A.:
- Cast iron flange-to-flange wedge gate valves with soft seals
- Gate valves with soft seals with threaded connection ends
- Gate valves with soft seals and ferrule connection ends
- Cast iron flange-to-flange wedge gate valves with soft seals for natural gas systems
- Cast iron annular wedge gate valves
4.5 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 warranty terms, conditions and period are specified in the relevant Warranty Sheet.