Jafar 5220 User manual

OPERATION AND MAINTENANCE MANUAL 01-2016
1
Operation and maintenance
manual for
BALL
VALVES
P/N
5220
5320
5321
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 design changes to the presented product.

OPERATION AND MAINTENANCE MANUAL 01-2016
2
CONTENTS
1 TECHNICAL DESCRIPTION........................................................................................................................... 3
1.1 PRODUCT DESIGNATION AND IDENTIFICATION.............................................................................. 3
1.2 USE............................................................................................................................................................... 3
1.3 TECHNICAL SPECIFICATION.................................................................................................................. 3
2 DESIGN.............................................................................................................................................................. 5
2.1 DESCRIPTION OF THE VALVE DESIGN................................................................................................ 5
2.2 MATERIALS................................................................................................................................................ 5
2.3 DIMENSIONS.............................................................................................................................................. 7
2.4 REFERENCE STANDARDS..................................................................................................................... 10
2.5 ORDERING INFORMATION................................................................................................................... 10
2.6 PRODUCTION AND ACCEPTANCE ...................................................................................................... 11
2.7 MARKINGS ............................................................................................................................................... 11
3 PROTECTION, STORAGE & TRANSPORT ................................................................................................. 11
3.1 PROTECTIVE COATINGS....................................................................................................................... 11
3.2 PACKAGING............................................................................................................................................. 11
3.3 STORAGE.................................................................................................................................................. 11
3.4 TRANSPORT ............................................................................................................................................. 11
4 ASSEMBLY AND INSTALLATION............................................................................................................... 12
4.1 ASSEMBLY GUIDELINES....................................................................................................................... 12
4.2 ASSEMBLY INSTRUCTIONS.................................................................................................................. 12
4.3 OPERATION.............................................................................................................................................. 15
4.4 OCCUPATIONAL HEALTH AND SAFETY........................................................................................... 15
5 WARRANTY TERMS AND CONDITIONS ................................................................................................... 15

OPERATION AND MAINTENANCE MANUAL 01-2016
3
1 TECHNICAL DESCRIPTION
1.1 PRODUCT DESIGNATION AND IDENTIFICATION
The subject of this Operation and Maintenance Manual is:
Flanged ball valve
TYPE 5220
- full bore design
- stainless steel free-floating ball (closure)
- stainless steel spindle
- spindle seal
- closure soft sealing
- sectional design
- optional drive actuator ready
TYPE 5320
- reduced bore design
- stainless steel free-floating ball (closure)
- stainless steel spindle
- spindle seal
- closure soft sealing
- monolithic design
- optional drive actuator ready
TYPE 5321
- reduced bore design
- stainless steel free-floating ball (closure)
- stainless steel spindle
- spindle seal
- closure soft sealing
- monolithic design
- optional drive actuator ready
1.2 USE
The TYPE 5220 & 5320 flanged and TYPE 5321 welded ends ball valves are intended for isolation of medium
flow in industrial systems, heating systems and other systems. (Group 2 fluids, ref. Directive 97/23/EC). The
valves can be operated both in underground and overground installations as installed in vertical or horizontal
pipelines.
NOTE:
Due to the limitations caused by application of specific materials in various operating environment
types, it is critical to precisely determine the operating conditions, i.e. the temperature, pressure and
medium characteristics. This will eliminate any problems during operation of the valve.
1.3 TECHNICAL SPECIFICATION
The ball valves are intended for isolation of medium flow in industrial systems, heating systems, and other
systems. (Group 2 fluids, ref. Directive 97/23/EC). The TYPE 5220, 5320 & 5321 steel and cast iron ends valves
are designed for operating temperatures of +160°C maximum. The operating parameters of each valve are indelibly
marked on the valve body.
Nominal diameter (dimension) and nominal pressure PN range:

OPERATION AND MAINTENANCE MANUAL 01-2016
4
- TYPE 5220 with flanged ends, diameter range: DN40-125[mm] - 16/25/40PN;
- TYPE 5220, cast iron, with flanged ends, diameter range: DN4-125[mm] - 16PN;
- TYPE 5320 with flanged ends, diameter range: DN15-50[mm] - 16/25/40PN;
DN50-300[mm] - 16/25PN;
- TYPE 5321 with welded ends, diameter range: DN15-50[mm] - 16/25/40PN;
DN15-300[mm] - 16/25PN.
Maximum medium flow rate:
- liquid: max. 4 [m/s]
- gas: max. 30 [m/s]
PN 16, PN 25 and PN 40 valve opening torque characteristics
Note: The nominal torque values can increase by 30% in actual operating conditions.
Valve control mode:
- the standard version of gate valves has the clockwise closing sense of rotation.
The valves are designed for installation between flange end faces acc. to PN-EN 1092-1: 2013
and PN-EN 1092-2: 1999 with bolt holes for the pressure rating of PN16/25/40. Installation length: per the
Technical File, see the table for sizes.
1
10
100
1000
10000
10 15 20 25 30 35 40 45
M [Nm]
PS [bar]
DN300
DN250
DN200
DN150
DN125
DN100
DN80
DN65
DN50
DN40
DN32
DN25
DN20
DN15
UWAGA: Wartości mome tów
omi al e. W waru kach
eksploatacyj ych wartości te mogą
NOTE: Nominal torque values given.
The values can increase by 30-50% in
actual operating conditions.

OPERATION AND MAINTENANCE MANUAL 01-2016
5
2 DESIGN
2.1 DESCRIPTION OF THE VALVE DESIGN
F.A. JAFAR S.A manufactures the TYPE 5220, 5320 & 5321 water ball valves, with the TYPE 5220 full bore
valves and the TYPE 5320 & 5321 reduced bore valves. The valve body is a welded structure with a free-floating
ball up to DN200 (larger sizes have trunnion balls), an internal compensation system, and a closure seal in the
form of a ball set in a seat, made by two seals. The ball seals are supported with disk springs to ensure continuous
pressure of the seals on the ball, even when the ball valve is operated at varying temperatures, and compensate the
thermal expansion of the valve. The chromium steel spindle, interfaced with the ball, is sealed within the valve
body by o-rings located on the cylindrical surface, and a Teflon seal on the conical surface. A manual control lever
is mounted on the valve spindle and formed as a steel handle coated with a plastic material; another form is a
mechanical drive gear. The turning angle limiter ensures proper positioning of the ball closure in the fully open
and fully closed positions. The ball valve is fully open with the control lever in parallel to the valve centreline, and
fully closed with the control level square to the valve centreline.
Ends:
- TYPE 5220 & 5320 flanged ends are designed per PN-EN 1092-1:2013
and PN-EN 1092-2:1999;
- TYPE 5321 welded ends are designed per PN-EN 12627:2002.
2.2 MATERIALS
The tables below list the structural materials of the TYPE 5120, 5121, 5124, 5220, 5320 & 5321 ball valves.
TYPE 5220
Item Part designation Material Reference standard
1Body
Steel grade 1.0582
Steel grade 1.0037
Cast-iron, EN-GJS-400-
15
PN-EN ISO 3183:2013
PN-EN 10025-2:2007
PN-EN 1563:2012
2Ball Steel grade 1.4301 PN-EN 10088-1: 2014
3Spindle Steel grade 1.4021 PN-EN 10088-1: 2014
4Screw plug Steel grade 1.0037 + Zn PN-EN 10025-2:2007
5Ball seal PTFE+C PN-EN ISO 13000-1:2007
6Turn limiter Steel grade 1.4301 PN-EN 10088-1: 2014
7 Spindle seal PTFE+C PN-EN ISO 13000-1:2007
8
9O-ring EPDM, VITON PN-ISO 1629:2005
10
11 Retaining ring PN-81/M-85111

OPERATION AND MAINTENANCE MANUAL 01-2016
6
TYPE 5320
Item Part designation Material Reference standard
1
2Body Steel grade 1.0425 PN-EN 10028-2:2010
3 Spring Steel grade 1.8159 PN-EN 10270-3:2011
4Ball Steel grade 1.4541
Steel grade 1.4301 PN-EN 10088-1: 2014
5 Ball seal PTFE+C PN-EN ISO 13000-1:2007
6Seal mount Steel grade 1.0425 PN-EN 10028-2: 2010
7Nut Steel, Fe/Zn5
Stainless steel, A4 PN-EN ISO 4032:2013
8Spindle Steel grade 1.4301 PN-EN 10088-1: 2014
8
9O-ring EPDM, VITON PN-ISO 1629:2005
10 Handle Steel grade 1.0038 PN-EN 10025-2:2007
TYPE 5321
Item Part designation Material Reference standard
1
2Body Steel grade 1.0425 PN-EN 10028-2:2010
3 Spring Steel grade 1.8159 PN-EN 10270-3:2011
4Ball Steel grade 1.4541
Steel grade 1.4301 PN-EN 10088-1: 2014
5 Ball seal PTFE+C PN-EN ISO 13000-1:2007
6Seal mount Steel grade 1.0425 PN-EN 10028-2: 2010
7Nut Steel, Fe/Zn5
Stainless steel, A4 PN-EN ISO 4032:2013
8Spindle Steel grade 1.4301 PN-EN 10088-1: 2014
8
9O-ring EPDM, VITON PN-ISO 1629:2005
10 Handle Steel grade 1.0038 PN-EN 10025-2:2007

OPERATION AND MAINTENANCE MANUAL 01-2016
7
2.3 DIMENSIONS
- TYPE 5220 (flanged ball valve)
TYPE 5220 table

OPERATION AND MAINTENANCE MANUAL 01-2016
8
bar m3/h kg
40 77 150 88 110 4x18 90 11 18 105 4,6
50 86 165 102 125 4x18 98 17 20 163 6,1
65 106 185 122 145 8x18 112 17 22 275 8,2
80 120 200 138 160 8x18 130 22 24 418 9,5
100 160 25/40 235 162 190 8xM20 147 22 26 654 16,6
125 186 25/40 270 188 220 8xM24 164 22 28 1023 23,5
40 77 150 88 110 4x19 90 11 105 5,4
50 86 165 102 125 4x19 98 17 163 6,8
65 106 185 122 145 8x19 112 17 275 9,7
80 120 200 138 160 8x19 130 22 418 11,2
100 160 220 158 180 8xM16 147 22 654 17,3
125 186 250 188 210 8xM16 164 22 1023 24,5
Steel
KvlxnK
21916
dD
16/25/40
Cast iro
2
c Weight
mm
mm
mm
DN L PN H S f
- TYPE 5320 (reduced bore flanged ball valve)
TYPE 5320 table

OPERATION AND MAINTENANCE MANUAL 01-2016
9
DN PN L Dk D C d H f K n l A
Weight
[mm] [bar] [pcs.] [kg]
15 16 / 25 / 40 130 10 95 14 45 70 2 65 4 14 120 1,7
20 16 / 25 / 40 150 15 105 16 58 70 2 75 4 14 120 2,4
25 16 / 25 / 40 160 20 115 16 68 85 2 85 4 14 150 3,0
32 16 / 25 / 40 180 25 140 18 78 90 2 100 4 18 150 4,6
40 16 / 25 / 40 200 32 150 18 88 125 2 110 4 18 190 5,6
50 16 / 25 / 40 230 40 165 20 102 125 2 125 4 18 190 7,5
16 20 8 (4) 280 11,0
25 22 8 280 11,6
16 20 280 13,2
25 24 280 14,7
16 220 22 158 180 18 280 16,7
25 235 26 162 190 22 280 19,9
16 250 22 210 18 420 25,8
25 270 28 220 26 420 31,2
16 285 24 212 240 22 550 34,4
25 300 30 218 250 26 550 40,5
16 340 26 268 295 22 - 72,0
25 360 32 278 310 26 - 81,0
16 405 29 320 355 26 - 100,0
25 452 35 335 370 30 - 111,8
16 460 32 378 410 12 26 - 200,0
25 485 38 395 430 16 30 - 215,1
145
150
[mm] [mm]
145 18
2 160
2
8 18
125
8
325 100 188 2 8
65 270 50 185 122
8
80 280 65 200 138
100 300 80 2
-300 630 250 2
250 530 200 2 12-
150 350 125 2
170
180
210
200 400 150 2 12260
- TYPE 5321 (reduced bore welded ends ball valve)
TYPE 5321 table

OPERATION AND MAINTENANCE MANUAL 01-2016
10
DN PS L Dk Dz g H A Kv Weight
[mm] [bar] [m
3
/h] [kg]
15 40 230 10 21,3 3,1 50,7 120 6 0,8
20 40 230 15 26,9 2,3 53,5 120 14 1,0
25 40 230 20 33,7 2,6 56,9 150 26 1,3
32 40 260 25 42,4 3 60,2 150 41 1,6
40 40 260 32 48,3 3 83,2 190 67 2,2
50 40 300 40 60,3 3 89,2 190 105 3,0
65 25 300 50 76,1 3 109,1 280 182 4,8
80 25 300 65 88,9 4 121,5 280 315 6,7
100 25 325 80 114,3 4 149,2 280 420 9,9
125 25 325 100 139,7 4,5 164,9 420 650 14,5
150 25 350 125 168,3 6 187,2 550 1070 23,5
200 25 400 150 219,1 4,5 224,5 - 1420 56,0
250 25 530 200 273,1 5 267,5 - 2620 100,0
300 25 550 250 323,9 5,6 317 - 5820 152,0
[mm]
2.4 REFERENCE STANDARDS
PN-EN 1074-2:2003 Valves for water supply. Fitness for purpose requirements and appropriate
verification tests.
Part 2: Isolating valves.
PN-EN 1983:2008 Industrial valves. Steel ball valves.
PN-EN 12266-1: 2012 Industrial valves. Testing of valves. Part 1: Pressure tests, test procedures and
acceptance criteria. Mandatory requirements.
PN-EN 1092-1: 2013 Flanges and their joints. Circular flanges for pipes, valves, fittings and
accessories, PN designated. Part 1: Steel flanges.
PN-EN 12266-2: 2012 Industrial valves. Testing of valves. Part 2: Pressure tests, test procedures and
acceptance criteria. Supplementary requirements.
PN-EN ISO 9692-2: 2002 Welding and allied processes. Joint preparation.
Part 2: Submerged arc welding of steels.
PN-EN 10088-1: 2014 Stainless steels. List of stainless steels.
PN-89/H-84023.05 Special use steel. Improved quality low-carbon, low-alloy and alloy steels.
Grades.
PN-EN ISO 12944-5: 2009 Paints and varnishes. Corrosion protection of steel structures by protective
paint systems. Protective paint systems.
PN-EN 19: 2005 Industrial valves. Marking of metallic valves.
PN-EN ISO 4017: 2011 Hexagon head screws. Product grades A and B.
PN-EN ISO 4027: 2006 Hexagon socket set screws with cone point.
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)
- nominal diameter DN, acc. to PN-EN ISO 6708: 1998
- nominal pressure PN, acc. to PN-89/H-02650;