Jafar 3160 User manual

OPERATING AND MAINTENANCE MANUAL 11-2015
Operation
and Maintenance Manual
CAST IRON THREADED AND FLANGED
PIPE CLAMPS
Cat. no.
3 50, 3 60, 3 5
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.

OPERATING AND MAINTENANCE MANUAL 11-2015
2
TABLE OF CONTENTS
1 TECHNICAL DESCRIPTION............................................................................................................................ 3
1.1 PRODUCT NAME AND FEATURES......................................................................................................... 3
1.2 PURPOSE..................................................................................................................................................... 3
1.3 TECHNICAL SPECIFICATION.................................................................................................................. 3
2 DESIGN............................................................................................................................................................... 3
2.1 FITTING DESIGN DESCRIPTION............................................................................................................. 3
2.2 MATERIALS................................................................................................................................................ 3
2.3 DIMENSIONS.............................................................................................................................................. 4
2.4 STANDARDS............................................................................................................................................... 7
2.5 ORDERING REGULATIONS ..................................................................................................................... 7
2.6 MANUFACTURE AND ACCEPTANCE.................................................................................................... 8
2.7 MARKING.................................................................................................................................................... 8
3 PROTECTION, STORAGE & TRANSPORT.................................................................................................... 8
3.1 PROTECTIVE COATINGS......................................................................................................................... 8
3.2 PACKAGING............................................................................................................................................... 8
3.3 STORAGE.................................................................................................................................................... 8
3.4 TRANSPORT ............................................................................................................................................... 8
4 ASSEMBLY AND INSTALLATION................................................................................................................. 9
4.1 INSTALLATION GUIDELINES................................................................................................................. 9
4.2 INSTALLATION INSTRUCTIONS............................................................................................................ 9
4.3 OH&S REGULATIONS............................................................................................................................. 10
5 GUARANTEE CONDITIONS.......................................................................................................................... 11

OPERATING AND MAINTENANCE MANUAL 11-2015
3
1 TECHNICAL DESCRIPTION
1.1 PRODUCT NAME AND FEATURES
The subject of this O&MM is:
Cast iron threaded pipe clamp type 3150, with soft lining (elastomer) of the internal clamping surface
for the line pipe of the water system.
Cast iron threaded pipe clamp type 3160, with soft lining (elastomer) of the internal clamping surface
for the line pipe of the water system.
Cast iron flanged pipe clamp type 3151, with soft lining (elastomer) of the internal clamping surface for
the line pipe of the water system.
1.2 PURPOSE
The cast iron threaded pipe clamps type 3150 and 3160 as well as cast iron flanged pipe clamps type
3151 are intended for water supply systems, especially for potable water, industrial systems and gas systems
made of polyethylene (PE) and polyvinyl chloride (PVC). They may be used both in underground and
surface installations, in vertical or horizontal pipelines.
1.3 TECHNICAL SPECIFICATION
The cast iron pipe clamps with soft lining are intended for transporting potable or industrial water and
other liquids (if approved by the manufacturer).
- temperature range: -10°C to +70°C
- line pipe diameter range: see the size table, accordingly for each type
- maximum medium flow rate: - liquid: max. 4 [m/s]
- gas: max. 30 [m/s]
-the connection thread design is acc. to PN-EN 10226-1: 2006
normal product grade [A].
-connection flanges are manufactured in accordance with PN-EN 1092-2: 1999
with the sizes compliant with the nominal pressure values.
-installation length: in accordance with plant documentation
-nominal pressure PN: – 0.6 MPa
– 1.0 MPa
– 1.6 MPa
2 DESIGN
2.1 FITTING DESIGN DESCRIPTION
The factory “JAFAR” S.A supplies cast iron clamps with threaded and flange connections. The body of the
clamp is a semi-annular cast iron casting with an element allowing for connection of a discharge pipe with a
threaded or flanged connection. The second semi-annular element is the bottom section of the clamp. Both parts
are connected with bolts that allow for clamping it on the pipe to seal it. Between the body of the clamp and the
line pipe there is rubber lining which acts as the mount.
After clamping the unit with bolts connecting both halves of the clamp it is possible to drill an opening in the
pipeline and make an offtake connection.
2.2 MATERIALS
This table lists the materials used in the construction of pipe clamps with soft seals.

OPERATING AND MAINTENANCE MANUAL 11-2015
4
Item
Part name Material Reference standard
1Body Cast iron: EN-GJS-400-15 PN-EN 1563: 2012
2Pipe gasket Rubber: EPDM (or NBR) PN-ISO 1629: 2005
3 Pipe gasket Rubber: EPDM (or NBR) PN-ISO 1629: 2005
4Pipe gasket Rubber: EPDM (or NBR) PN-ISO 1629: 2005
5 Clamp Cast iron: EN-GJS-400-15 PN-EN 1563: 2012
6Bolt Stainless steel, A2 PN-EN ISO 4014: 2011
7Washer Stainless steel, A2 PN-EN ISO 7091: 2003
8Nut Stainless steel, A4 PN-EN ISO 4032: 2013
2.3 DIMENSIONS
Threaded cast iron clamp type 3150
m L
[mm]
DN G Dz
4050 2”
63
90
110
122160
145200
94
84
70
225
270
180
160
132
6,8
9,3
5,0
4,4
3,5
Hweigh
[kg]
2
2
154225
163250
300
320
10,4
13,5
2
2
2
2
2
number of
bolts
[pcs.][mm] [inch]
125 102 200 5,8 2
176280 196315 340
370 14,2 16,7 2 2

OPERATING AND MAINTENANCE MANUAL 11-2015
5
Threaded cast iron clamp type 3160
[mm] [inch] [kg] [pcs.]
90
87
135
2,6
4
110
95
162
3,3
4
125
112
178
4,1
4
160
121
202
4,7
4
180
141
230
5,2
4
LDN HDzG
3160
50 2" 40
Weiht Number of
bolts
[mm]
m

OPERATING AND MAINTENANCE MANUAL 11-2015
6
Flanged cast iron clamp type 3151
50 63 129 140 165
50 75 141 140 165
50 90 161 145 165
50 140 165
80 170 200
50 160 165
80 170 200
50 160,0 165
80 170 200
100 180 220
50 170 165
80 200 200
100 205 220
50 195 165
80 225 200
100 230 220
50 195 165
80 225 200
100 230 220
50 195 165
80 225 200
100 230 220
50 205 165
80 225 200
100 230 220
50 250 165
80 250 200
100 255 220
150 265 185
50 260 165
80 265 200
100 270 220
150 280 285
50 290 165
80 295 200
100 300 220
150 310 285
50 340 165
80 350 200
100 360 220
150 370 285
125 204
110
H L
[mm]
DN DDz
140
160
180
200
219,1
225
376
250
280
315 411
496400
304
345
189
219
239
259
279
298

OPERATING AND MAINTENANCE MANUAL 11-2015
7
2.4 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 Fittings and pipelines. Pressures and temperatures for
fittings, connectors and equipment with PN markings. Cast iron flanges.
PN-EN19: 2005 Industrial fittings. Metal fitting marking.
PN-EN 12266-1: 2012 Industrial valves. Testing of metallic valves. Pressure tests, test procedures
and acceptance criteria.
Mandatory requirements.
PN-EN ISO 6708: 1998 Definition and selection of the DN /nominal dimension/
PN-EN 10226-1: 2006 Pipe threads where pressure tight joints are made on the threads - Part 1:
Taper external threads and parallel internal threads.
Dimensions, tolerances and designation
PN-ISO 965-1: 2001 ISO general purpose metric screw threads. Tolerances. Principles and basic
data.
PN-ISO 2903: 1996 Trapezoid ISO metric threads. Tolerances.
PN-EN 1092-2: 1999 Flanges and their connections. Circular flanges for pipes,
fittings, connectors and equipment with PN markings. Cast iron flanges.
PN-EN ISO 4032: 2013 Hexagon regular nuts (style 1). Product grades A and B.
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. Examination of surface condition by
visual-tactile comparators.
PN-EN ISO 7091: 2003 Plain washers. Normal series. Product grade C
PN-EN 10088-1: 2014 Stainless steels. Grades of stainless steel.
PN-74/H-84032 Spring steel. Grades.
PN-EN ISO 4762: 2006 Hexagon socket head cap screws.
PN-EN ISO 4017: 2004 Hexagon head screws. Product grades A and B.
PN-EN 10204: 2006 Metallic products. Types of inspection documents.
PN-ISO 1629: 2005 Rubbers and latices. Nomenclature.
PN-EN ISO 1872-1: 2000 Plastic materials. Polyethylene (PE) moulding and extrusion materials.
Designation system and basis for specifications.
PN-EN ISO 1873-1: 2000 Plastic materials. Polypropylene (PP) moulding and extrusion materials.
Designation system and basis for specifications.
PN-EN ISO 1874-1: 2010 Plastic materials. Polyamide (PA) forming and extrusion moulding materials.
Designation system and basis for specification.
PN-EN ISO 12944-5: 2009 Paints and varnishes. Anti-corrosion protection of steel structures by means of
protective painting systems. Protective painting systems.
2.5 ORDERING REGULATIONS
Water supply system fittings are specific purpose industrial fittings, therefore orders must include:
- catalogue number,
- intended use, e.g. for water supply systems,
furthermore:
- 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
- max. operating temperature — acc. to PN-89/H — 02650.

OPERATING AND MAINTENANCE MANUAL 11-2015
8
2.6 MANUFACTURE AND ACCEPTANCE
Cast-iron pipe clamps with catalogue numbers 3150, 3151, 3160 are accepted and manufactured in
accordance with: PN-EN 1074-1:2002 (Valves for water supply. Fitness for purpose requirements and
appropriate verification tests. General requirements) and PN-EN 12266-1:2012 (Industrial valves. Testing of
metallic valves). All clamps are leak tested (100%). The tests include external body tightness.
2.7 MARKING
The clamp marking meets the following standards: PN-EN-19: 2005, PN-EN-1074-1: 2002.
The bodies of cast iron clamps have a marking on the front side, containing:
- clamp type (specified as number of standard applicable to product),
- manufacturer trade mark.
the rear side of the body neck contains:
- nominal diameter
- nominal pressure
- body material type
The location specified in the documentation features the nameplate which contains the following data:
- company name and mark
- product 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 internal and external cast iron surfaces are protected with epoxy paint, applied electrostatically. The paint
is approved for contact with food products.
The thickness of the anti-corrosion coating layer is min. 250 µm.
The casting surface is pre-treated for epoxy coating in accordance with the relevant technical documentation and
standard PN-EN ISO 12944-5: 2009.
The screws connecting the body and the clamp are manufactured as stainless, grade 1.4301 or Fe/Zn5 (galvanised
steel).
3.2 PACKAGING
Pipe clamps are packaged on EURO pallets (1200x800) and protected with shrink film.
3.3 STORAGE
Store the cast iron pipe clamps in sheltered rooms.
3.4 TRANSPORT
Transport the cast iron pipe clamps using sheltered vehicles.

OPERATING AND MAINTENANCE MANUAL 11-2015
9
4 ASSEMBLY AND INSTALLATION
4.1 INSTALLATION GUIDELINES
The cast iron pipe clamps TYPE 3150, 3160 and 3151 are appropriate for installation on the line pipe
without the necessity of using additional sealing. Before installing the pipe clamp, it is recommended to lubricate
the sealing assembly surfaces with industrial grade petroleum jelly to prevent adhesion and possible damage
during the removal of rubber components. After joining both sides of the clamp, it should be centred and then
tightened evenly with installation screws. Following assembly check if the unit is installed correctly. It is now
possible to make an opening in the line pipe. The pipe clamp installed in the pipeline is its integral part and does
not require using additional supports (bearing plates) below it.
The pipe clamp assembled and adjusted by the manufacturer is ready for installation. Any dismantling of the
sealing components may result in loss of tightness.
4.2 INSTALLATION INSTRUCTIONS
Before installing the fittings, check the technical and commercial documentation, i.e. application for media
and operation parameters of the pipeline, in which they are to be installed. Any change in the operating
conditions must be consulted with the fitting manufacturer beforehand.
Before attempting to assemble the fitting, remove the main bore plugs, check the inner surfaces of the
clamp and thoroughly flush with water, if necessary.
The installation of a threaded pipe clamp type 3150 is presented in the drawing below:
1.-clamp body, 2.-clamp, 3.-pipeline, 4.- screw 2 pcs., 5.-nut 2 pcs., 6.-washer 2 pcs.,

OPERATING AND MAINTENANCE MANUAL 11-2015
10
The installation of a threaded pipe clamp type 3160 is presented in the drawing below:
1.-clamp body, 2.-clamp, 3.-pipeline, 4.- screw 4 pcs., 5.-nut 4 pcs., 6.-washer 4 pcs.,
The installation of a flanged pipe clamp type 3151 is presented in the drawing below:
1.-clamp body, 2.-clamp, 3.-pipeline, 4.- screw 8 pcs., 5.-nut 8 pcs., 6.-washer 8 pcs.,
4.3 OH&S REGULATIONS
The OH&S guidelines and recommendations 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 the Polish Regulation concerning general OH&S regulations (use of personal protective equipment
for hands, legs and head, and safety garments), especially at work with low or high temperature hazard apply to
the pipe clamps.
Misuse of this product is prohibited.

OPERATING AND MAINTENANCE MANUAL 11-2015
11
5 GUARANTEE CONDITIONS
The manufacturer grants guarantee for the product being installed and operated according to this
O&MM. The conditions and period of the guarantee is specified in the guarantee sheet.