Jafar 9202 User manual

OPERATION AND MAINTENANCE MANUAL 01-2016
Operation and Maintenance Manual
DOUBLE FLANGE BEND
With the N foot
FLANGE T-PIE E
TT FLANGE X-PIE E
at. no.
9202; 9203; 9218
Approved for use by
JAFAR S.A. Factory President
Failure to comply with the guidelines and instructions in this Operation and
Maintenance Manual exempts the manufacturer from all obligations, liabilities and
guarantees.
Due to the continuous development of our business, we reserve the right to introduce
modifications and structural changes to the product presented herein.

OPERATION AND MAINTENANCE MANUAL 01-2016
2
TABLE OF CONTENTS
1 TECHNICAL DESCRIPTION............................................................................................................................ 3
1.1 PRODUCT NAME AND FEATURES......................................................................................................... 3
1.2 INTENDED USE.......................................................................................................................................... 3
1.3 TECHNICAL SPECIFICATION.................................................................................................................. 3
2 DESIGN............................................................................................................................................................... 3
2.1 FITTING DESIGN DESCRIPTION............................................................................................................. 3
2.2 MATERIALS................................................................................................................................................ 4
2.3 DIMENSIONS.............................................................................................................................................. 4
2.4 STANDARDISATION................................................................................................................................. 6
2.5 ORDERING REGULATIONS ..................................................................................................................... 7
2.6 MANUFACTURE AND ACCEPTANCE.................................................................................................... 7
2.7 MARKINGS ................................................................................................................................................. 7
3 PROTECTION, STORAGE & TRANSPORT.................................................................................................... 7
3.1 PROTECTIVE COATINGS......................................................................................................................... 7
3.2 PACKAGING............................................................................................................................................... 7
3.3 STORAGE.................................................................................................................................................... 7
3.4 TRANSPORTATION................................................................................................................................... 8
4 ASSEMBLY AND INSTALLATION................................................................................................................. 8
4.1 INSTALLATION GUIDELINES................................................................................................................. 8
4.2 INSTALLATION INSTRUCTIONS............................................................................................................ 8
4.3 OPERATION.............................................................................................................................................. 10
4.4 OH&S REGULATIONS............................................................................................................................. 10
5 GUARANTEE CONDITIONS.......................................................................................................................... 10

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1 TECHNICAL DESCRIPTION
1.1 PRODUCT NAME AND FEATURES
The subject of this O&MM are:
The double flange bend with the N foot of type 9202, intended for piping systems and used as an element to
divert the direction of the medium flow from vertical to horizontal or the other way around.
The flange T-piece of type 9203, intended for piping systems and used as an element to divert the direction
of the medium flow from vertical to horizontal or the other way around.
The flange X-piece of type 9218 TT, intended for piping systems and used as an element to divert the
direction of the medium flow from vertical to horizontal or the other way around.
1.2 INTENDED USE
The bend of type 9202, T-pieces of type 9203 and X-pieces of type 9218 TT are intended for mounting
installations of any pipes terminated with flange connections.
They can be operated both in underground and overground installations as installed in vertical or horizontal
pipelines.
1.3 TECHNICAL SPECIFICATION
The bend of type 9202, T-pieces of type 9203, X-piece of type 9218 TT are used for transporting potable
and industrial water and other liquids (to be determined with the manufacturer)
- temperature from -10
o
C to +70
o
C.
- scope of applied diameters of line pipes according to the table with dimensions
for each type
- maximum medium flow rate:- liquid: max. 4 [m/s]
- gas: max. 30 [m/s]
connections of bends and T-pieces are prepared for mounting flange pipes as big as required by the adopted
nominal pressure according to PN-EN 1092-2: 1999.
2 DESIGN
2.1 FITTING DESIGN DESCRIPTION
"JAFAR" S.A. Fitting Factory provides bends of type 9202, T-pieces of type 9203 and X-pieces of type
9218 TT. A bend is an iron casting supported by a foot with a flange, which allows connecting a supply pipe via
a flange end on both sides. Bodies of T-pieces are T-shaped iron castings. Branch-offs are terminated with
flanges, which allow connecting a supply pipe via a flange end, used for diverting the direction from vertical to
horizontal and vice versa.
Note:
Bends of type 9202, T-pieces of type 9203 and X-pieces of type 9218 TT are typical couplers.

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2.2 MATERIALS.
The index of materials used for the production of foot bends of type 9202, T-pieces of type 9203 and X-
pieces of type 9218 TT is to be found in the table.
Pos. Part name Material Standard
1 Bend, T-piece body Ductile cast iron
EN-GJS500-7 PN-EN 1563:2012
2.3 DIMENSIONS
Double flange bend with the N foot of type 9202.
DN l
Weight
[kg]
80 165 13,0
100 180 17,0
150 220 29,0
200 260 46,0
250 350 73,0
300 400 104,0
400 500 177,0
500 600 281,0
600 700 425,0
800 900 860,0
[mm]

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Flange t-piece of type 9203.
DN dn L
Weight
DN dn L
Weight
DN dn L
Weight
[kg] [kg] [kg]
50 50 300 11,5 80 700 65,0 100 950 190,0
60 60 320 12,5 100 700 69,0 150* 570* 195*
50 310 14,2 150 700 70,0 200 950 205,0
60 310 14,6 200 700 80,0 250* 690* 211,0*
80 330 15,6 250 700 89,0 300* 745* 218,0*
40 320 17,8 80 800 93,0 450 950 240,0
50 320 18,5 100 800 97,0 80 1000 212,0
60 320 18,4 150 800 98,0 100 1000 215,0
65 320 20,0 200 800 101,0 150 1000 255,0
80 360 18,4 250 800 106,0 200 1000 262,0
100 360 19,3 300 800 125,0 250 1000 270,0
60* 330* 22,8* 150* 530* 123,0* 300 1000 274,0
80 400 23,1 200 850 129,0 400 1000 285,0
100 400 23,5 250* 645* 135,0* 500 1000 300,0
125 400 25,5 300 850 141,0 80 580 304,0
50* 340* 29,5* 350 850 167,0 200 1100 307,0
60* 340* 27,8* 80* 900 159,0* 400 1100 323,0
80 440 28,5 100* 900 161,0* 600 1100 350,0
100 440 29,5 150* 900 163,0* 200 690 350,0
150 440 32,5 200 900 169,0 400 910 430,0
50 520 43,2 250* 900 175,0* 800 1350 630,0
60 520 41,5 300* 900 179,0* 400 990 650,0
80 520 43,5 350* 900 185,0* 600 1650 990,0
100 520 44,5 400 900 198,0 - - - -
125 520 45,0
150 520 45,5
200 520 49,0
100
[mm]
450
150
200
250
350
400 800
1000
80
[mm]
125
300
[mm]
500
600
* - on request

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Flange X-piece of type 9218 TT.
DN L L1
Weight
[kg]
80 330 165 22,0
100 360 180 27,0
150 440 220 50,0
200 520 260 80,0
250 600 300 104,0
300 680 340 145,0
400 900 450 215,0
500 900 450 305,0
600 1100 550 420,0
[mm]
2.4 STANDARDISATION
PN-EN 1074-1: 2002 Pipeline fittings. Functional requirements and verification tests.
General requirements.
PN-EN 12266-1: 2007 Industrial fittings. Fitting testing.
PN-EN 19:2005 Industrial fittings. Metal fitting marking.
PN-89/H-02650 Fittings and pipelines. Pressures and temperatures.
PN-EN ISO 6708: 1998 Definition and selection of DN (nominal dimension).
PN-ISO 1629: 2005 Rubber and latex. Nomenclature.

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PN-EN 1092-2: 1999 Flanges and their connections. Circular flanges for pipes, fittings, couplers
and accessories with PN designation. Cast iron flanges.
PN-EN 1561: 2012 Founding. Grey cast iron.
PN-EN 1563: 2012 Founding. Ductile cast iron.
PN-EN ISO 12944-5: 2001 Paints and varnishes. Corrosion protection of steel structures by protective
paint systems. Protective paint 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
- body material type – acc. to PN-EN 1563: 2012
- max. operating temperature – acc. to PN-89/H – 02650.
2.6 MANUFACTURE AND ACCEPTANCE
The double flange bend with the N foot of type 9202, T-pieces of type 9203 and X-pieces of type 9218 TT
are accepted and produced in accordance with PN-EN 1074-1:2002 (Water supply system fittings. Functional
requirements and verification tests. General requirements) and PN-EN 12266-1:2007 (Industrial valves. Testing
of metallic valves). All fittings are tested for tightness (100%). Such tests include external unit tightness while
delivered.
2.7 MARKINGS
The marking of bends of type 9202, T-pieces of type 9203 and X-pieces of type 9218 TT is governed by the
following standards: PN-EN-19: 2005 and PN-EN-1074-1: 2002.
Bodies of bends of type 9202, T-pieces of type 9203 and X-pieces of type 9218 TT feature markings on
labels, stuck on walls of body necks. The markings contain the following data:
- coupler type (acc. to the product catalogue number /TYPE/)
- nominal diameter
- nominal pressure
- body material type
- manufacturer's trademark
and identification mark: (e.g. series no.)
3 PROTECTION, STORAGE & TRANSPORT
3.1 PROTECTIVE COATINGS
All internal and external cast iron surfaces are secured with epoxy paint applied electrostatically. The paint is
approved for contact with food products.
The anti-corrosion coat layer thickness is min. 250 µm.
The casting surface is pre-treated for epoxy coating in accordance with the relevant technical documentation and
PN-EN ISO 12944-5:2001.
3.2 PACKAGING
Bends of type 9202, T-pieces of type 9203 and X-pieces of type 9218 TT are packaged on EURO pallets
(1200x800) and secured with stretch foil.
3.3 STORAGE

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Bends of type 9202, T-pieces of type 9203 and X-pieces of type 9218 TT should be stored indoors.
3.4 TRANSPORTATION
Bends of type 9202, T-pieces of type 9203 and X-pieces of type 9218 TT should be transported by sheltered
vehicles.
Schematic drawing of how the X-piece of type 9218 TT from DN100 – DN600, double flange bend with
the N foot of type 9202 from DN80 – DN800 and flange T-piece of type 9203 from DN50 – DN1000 should be
mounted for transport by use of slings. Use slings to transport the items mentioned above.
4 ASSEMBLY AND INSTALLATION
4.1 INSTALLATION GUIDELINES
The double flange bend with the N foot of type 9202, T-pieces of type 9203 and X-pieces of type 9218 TT
are tailored to being mounted at a line pipe of a pipeline with the application of additional flange-to-flange seals.
Before mounting the bend, it is recommended lubricating the surface of the sealing system with technical
vaseline, which will prevent rubber elements from adhering and being damaged in the course of disassembly
works. Insert the bend or T-piece into the prepared section of the pipeline, connect one of its flanges with the line
pipe, while the other flange to the vertical pipe connection. Connect the flanges by using a flange-to-flange seal.
Centre both pipe ends. Following the assembly, check if the T-piece or bend is installed correctly.
Bends and T-pieces delivered by the manufacturer are ready to be assembled at the installation. Any works
related to the disassembly of sealing elements can lead to the loss of tightness.
4.2 INSTALLATION INSTRUCTIONS
Before installing the fittings, check the technical and commercial documentation, i.e. application of
media and operation parameters of the pipeline in which they are to be installed. Before the assembly
works, remove the sealing of the main pass, if any; check the condition of the inner surfaces of the coupler and, if
necessary, carefully wash them with water.
Any change in the operating conditions must be consulted with the fitting's manufacturer.
Method for the installation of a double flange foot bend of type 9202 is presented in the diagram below:

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1.- bend pipe, 2.- pipeline flanges 3.- flange seal, 4- mounting bolt, 5.- washer, 6.- nut.
Method for the installation of a flange T-piece of type 9203 is presented in the diagram below:
1.- T-piece, 2.- pipeline flanges 3.- flange seal, 4- mounting bolt, 5.- nut, 6.- washer.

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Method for the installation of a flange X-piece of type 9218 TT is presented in the diagram below:
1.- X-piece, 2.- pipeline flange, 3.- flange seal, 4.- mounting bolt, 5.- nut, 6.- washer.
4.3 OPERATION
Bends of type 9202, T-pieces of type 9203 and X-pieces of type 9218 TT should be operated according to
requirements pertaining to connection fittings.
4.4 OH&S REGULATIONS
Bends of type 9202, T-pieces of type 9203 and X-pieces of type 9218 TT are subject to guidelines and
recommendations included in H&S regulations applicable to the installation of pipelines and equipment in: water
supply stations, thermal power stations, sewage treatment plants, intermediate pumping stations and other
structures, as well as general health and safety regulations (use of upper limb protection equipment, lower limb
protection equipment, head protection equipment and protective clothing), in particular during works with low
and high temperature exposure.
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 are specified in the guarantee sheet.