Jafar 6534 Installation guide

OPERATION AND MAINTENANCE MANUAL 01-2016
Operation and maintenance
manual for
FLANGE-TO-FLANGE
CHECK
FLAP
VALVES
P/N
534
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 continuous business development, we reserve the right to introduce
modifications and structural changes to the presented product.

OPERATION AND MAINTENANCE MANUAL 05/2015
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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.............................................................................................................................................. 4
2.4 REFERENCE STANDARDS....................................................................................................................... 5
2.5 ORDERING INFORMATION ..................................................................................................................... 5
2.6 PRODUCTION AND ACCEPTANCE ........................................................................................................ 5
2.7 MARKINGS ................................................................................................................................................. 5
3 PROTECTION, STORAGE & TRANSPORT................................................................................................... 6
3.1 PACKAGING............................................................................................................................................... 6
3.3 STORAGE.................................................................................................................................................... 6
3.4 TRANSPORT ............................................................................................................................................... 6
4 ASSEMBLY AND INSTALLATION................................................................................................................. 6
4.1 ASSEMBLY GUIDELINES......................................................................................................................... 6
4.2 ASSEMBLY INSTRUCTIONS.................................................................................................................... 7
4.3 OPERATION................................................................................................................................................ 7
4.4 OCCUPATIONAL HEALTH AND SAFETY ............................................................................................. 7
5 WARRANTY TERMS AND CONDITIONS...................................................................................................... 7

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1 TECHNICAL DESCRIPTION
1.1 PRODUCT DESIGNATION AND IDENTIFICATION
The subject of this Operation and Maintenance Manual is:
TYPE 6534 flange-to-flange check flap valve.
- with flap (closure)
- with o-ring seals
- with body and flap wafer made of steel grade 1.4301 or 1.0038/Zn.
1.2 USE
The Type 6534 flange-to-flange check flap valves are intended for industrial installations, e.g. sewage
discharge, or water supply systems, e.g. for potable water. The valves are intended for overground
installations as installed in vertical or horizontal pipelines.
1.3 TECHNICAL SPECIFICATION
The Type 6534 flange-to-flange check flap valves are designed to transport potable water, process
water (sewage) and other liquids as approved by the manufacturer.
- Operating temperature: -10°C to +70°C
- Available diameters (dimensions): - DN40 – DN300[mm]
- Maximum medium flow rate: - liquid: max. 4 [m/s]
- nominal pressure ratings (PN): - 1.0 MPa
- 1.6 MPa
2 DESIGN
2.1 DESCRIPTION OF THE VALVE DESIGN
F.A. JAFAR S.A manufactures the Type 6534 flange-to-flange check flap valves for industrial and water
supply systems. The valve body is made of stainless steel or zinc-plated carbon steel and houses a wafer flap as
the valve closure. In the operating conditions, the flap is held at the top position (under the inner pipe wall) by
the dynamic force of the liquid stream, or in the closed position, where it seals off the valve seat under the back
pressure.

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2.2 MATERIALS
The table below lists the structural materials of the check flap valves.
Item
Part designation Material Reference standard
1 Body Steel grade 1.0037
Steel grade 1.4310 PN-EN 10025-2:2007 PN-EN 10088-1:2014
2Cover Steel grade 1.0037
Steel grade 1.4310 PN-EN 10025-2:2007 PN-EN 10088-1:2014
3Spring* 50S2JR/Zn
Steel grade 1.4310 PN-74/H-84032 PN-EN 10088-1:2014
4Seal Rubber: EPDM PN-ISO 1629: 2005
5Eye bolt Steel grade 1.0037
Steel grade 1.4310 PN-EN 10025-2:2007 PN-EN 10088-1:2014
*not in standard version
2.3 DIMENSIONS
[kg]
40 94 21 15 0,5
50 109 30 15 0,8
65 129 41 15 1,3
80 144 50 17 1,5
100 164 75 17 2,3
125 195 96 18 3,0
150 221 96 18 4,5
200 276 155 28,5 9,3
250 330 200 33,5 15,0
300 384 240 38 24,0
[mm]
D E L Weight DN

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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 1074-3: 2002 Valves for water supply. Fitness for purpose requirements and appropriate
verification tests. Check 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-EN 19: 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 1563: 2012 Founding. Spheroidal graphite cast irons.
PN-EN 1370: 2012 Founding. Surface roughness inspection by
visual tactile comparators.
PN-ISO 965-1: 2001 General purpose ISO metric threads. Tolerances. Principles and basic data.
PN-EN ISO 4762: 2006 Hexagon socket head cap screws.
DIN 6912: 2006 Hexagon socket low 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 paint systems.
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 sewage;
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 1563: 2012
- maximum operating temperature, acc. to PN-89/H-02650
2.6 PRODUCTION AND ACCEPTANCE
The flange-to-flange check flap valves are manufactured and accepted in accordance with
PN-EN 1074-3: 2002 (Valves for water supply. Fitness for purpose requirements and appropriate verification
tests. Check valves) and PN-EN 12266-1: 2007 (Industrial valves. Testing of valves). All valves are leak tested
(100%). The tests include external body tightness and closing tightness at high and low pressure values.
2.7 MARKINGS
The valve marking is regulated by the following standards: PN-EN 19: 2005, PN-EN-1074-1: 2002.

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The valve bodies bear markings which read the following data:
- nominal diameter
- nominal pressure
- body material type
- manufacturer trademark
- flow direction arrow
3 PROTECTION, STORAGE & TRANSPORT
3.1 PACKAGING
The flange-to-flange check flap valves are packed on EURO pallets (1200x800) and protected with heat-
shrunk film.
3.3 STORAGE
Store the flange-to-flange check flap valves in
sheltered rooms.
3.4 TRANSPORT
Transport the flange-to-flange check flap valves on sheltered vehicles.
The check flap valves from DN250 to DN300 shall be installed and handled with slings.
4 ASSEMBLY AND INSTALLATION
4.1 ASSEMBLY GUIDELINES
The Type 6534 flange-to-flange check flap valves can be installed in underground or overground
pipelines both in horizontal or vertical orientation. The valves are suitable for joining with the flanged ends of

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pipelines with the size equal to the installation length. Note that the system must not expose the valve to bending
or tensile stress from loading with the unsupported pipeline sections. The valve assembled and delivered by the
manufacturer is ready for installation. Disassembly of the valve components without proper care may result in
loss of integrity.
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, check the inner surfaces of the valve and thoroughly flush with
water, if necessary.
Install the flange-to-flange check flap valve between the adjacent flanges of the pipeline ends and bolt
down by alternately tightening the opposite pin bolts. The assembly method is shown in the following figure:
CAUTION!
Install the valve downstream of a straight pipeline the length of which is at least 5 times the pipeline
nominal diameter.
4.3 OPERATION
The flange-to-flange check flap valves shall be operated according to the requirements for check valves. The
check flap valve has a self-cleaning action. However, it is recommended to periodically purge the valve with
fresh water (once a year) to assure full performance. Hard solids with the size above 5 mm should be filtered out
of the transmitted medium to prevent seizure of the flap inside the body and damage to the closure seal rubber
surface. If the flap is stuck, start the installation pump for a few seconds. If the problem persists, stop all
installation pumps, isolate the medium flow, and free the flap.
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

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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 warranty terms, conditions and period are specified in the
relevant Warranty Sheet.