Jafar 8003 User manual

OPERATION AND MAINTENANCE MANUAL 12-2015
Operation and Maintenance Manual
BREAK-AWAY FIRE HYDRANT
P/N
TYPE 003
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.

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TABLE OF CONTENTS
1 TECHNICAL DESCRIPTION............................................................................................................................ 3
1.1 PRODUCT NAME AND FEATURES......................................................................................................... 3
1.2 PURPOSE..................................................................................................................................................... 3
1.3 TECHNICAL SPECIFICATION.................................................................................................................. 3
2 STRUCTURE...................................................................................................................................................... 3
2.1 HYDRANT DESIGN DESCRIPTION......................................................................................................... 3
2.2 MATERIALS DN80..................................................................................................................................... 7
2.3 DIMENSIONS DN80 ................................................................................................................................... 8
2.4 MATERIALS DN100................................................................................................................................... 9
2.5 DIMENSIONS DN100 ............................................................................................................................... 10
2.6 STANDARDS............................................................................................................................................. 11
2.7 ORDERING REGULATIONS ................................................................................................................... 11
2.8 MANUFACTURE AND ACCEPTANCE.................................................................................................. 11
2.9 MARKINGS ............................................................................................................................................... 12
3 PROTECTION, STORAGE & TRANSPORT.................................................................................................. 12
3.1 PROTECTIVE COATINGS....................................................................................................................... 12
3.2 PACKAGING............................................................................................................................................. 12
3.3 STORAGE.................................................................................................................................................. 12
3.4 TRANSPORT ............................................................................................................................................. 13
4 ASSEMBLY AND INSTALLATION............................................................................................................... 13
4.1 INSTALLATION GUIDELINES............................................................................................................... 13
4.2 INSTALLATION INSTRUCTIONS.......................................................................................................... 14
4.3 OPERATION.............................................................................................................................................. 15
4.4 OH&S REGULATIONS............................................................................................................................. 15
5 GUARANTEE CONDITIONS.......................................................................................................................... 15

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1 TECHNICAL DESCRIPTION
1.1 PRODUCT NAME AND FEATURES
The subject of this O&MM is:
Break-away fire hydrant with double closure
- With additional protection against flow in the form of ball valve;
placed below poppet
- With automatic water drainage activated by medium flow stoppage;
- With poppet (closure) embedded in 100% pure elastomer;
- Internal parts may be replaced without cutting off flow;
- Valve body with saddle tees may be rotated within the range from 0
o
to 360
o
.
1.2 PURPOSE
Break-away fire hydrants TYPE 8003 with double closure are intended for fire protection systems, for
chemically neutral pure water, free of impurities and for industrial systems. For use on above-ground
installations on pipelines laid horizontally below the freezing zone.
1.3 TECHNICAL SPECIFICATION
Break-away fire hydrants with closure are intended for transport of potable water and industrial
water at temperatures from +1°C to +50°C.
- Available diameters (dimensions) DN80-DN100 [mm]
- Maximum medium flow rate: - liquid up to 4 [m/s]
- driving torque at opening start and closing end are listed below:
DN [mm]
80 100
Mmax [Nm]
80 80
- equipment control: closing direction in the standard version of hydrant:
clockwise closing sense of rotation.
The closing sense of rotation can be opposite on special order.
-connection flanges are manufactured in accordance with PN-EN 1092-2:1999
with the dimensions adequate to the relevant nominal pressure of 1.6 MPa.
-Hydrant's efficiency with nominal pressure 0.2 MPa is:
10 dm
3
/s – above ground DN80
15 dm
3
/s – above ground DN100
In accordance with PN-B-02863: 1997 "Fire water supply"
-Key for controlling valves and taps PN-89/M-74088
-Design in accordance with PN-EN 14384:2009 TYPE C
-Saddle tees B 75 per DIN 14318: 1985
-Saddle tees A 110 per DIN 14319: 1985
2 STRUCTURE
2.1 HYDRANT DESIGN DESCRIPTION
The fire hydrants are made in the form of column with internal structure to enable drawing water from
pipeline and a header with saddle tees for attachment of fire hoses. In the lower part of the hydrant there is a cast-
iron valve chamber with a poppet acting as closing element and a drainage device. The chamber housing is
connected to the ball's (ball return valve) valve chamber finished with a connection flange for installing the
hydrant on the pipeline. Top part of the hydrant is a cast-iron body with outlet openings with saddle tees. The top
body also has a driving element on the end of bolt used for transferring rotational movement to the hydrant's
poppet via distance pipe. The top body of a break-away fire hydrant is connected to the underground part with

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thinner bolts. Such a connection enables breakage of hydrant without damaging it and resulting water outflow.
Special flanges enable free rotation of the ground part of the hydrant from 0° to 360°. There is a special
articulation spindle inside the hydrant, in the connection area of the above ground and underground part of the
hydrant. The rotating stem is seated in a stopper with rubber sealing rings. Rotate the hydrant clockwise to close
the flow. Poppet moves during rotation of the stem and flow opens. The poppet's movement closes the water
draining device's outlet opening. When closing a hydrant, the poppet lands in the seat and the water remaining in
the hydrant's column using draining valve.
With this type of hydrant, it is possible to replace the complete internal equipment of a hydrant without cutting
off the supply thanks to a ball valve.

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Operation diagram for hydrant TYPE 8003 DN80
CLOSE OPEN

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Operation diagram for hydrant TYPE 8003 DN100
CLOSE OPEN
The order of operations during opening and closing of a hydrant type 8003 configured with a shutoff gate
valve.
- Starting:
1. Open the shutoff gate valve.
2. Open the hydrant.
- Stopping:
3. Close the hydrant.
4. Close the shutoff gate valve.

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Caution! It is prohibited to open this type of hydrant with a closed shutoff gate valve because the poppet
sliding down must be able to push a water column in the direction opposite to the flow direction during
the first phase of its movement.
2.2 MATERIALS DN80
List of basic materials used for the construction of an overground hydrant TYPE 8003 DN80 —
See table
Item
Part name Material Reference standard
1Main body Cast-iron, EN-GJS 400-15
EN-GJS500-7 PN-EN1563: 2012
2 Ball chamber Cast-iron, EN-GJS 400-15
EN-GJS500-7 PN-EN1563: 2012
3Column
Cast-iron, EN-GJS 400-15
EN-GJS500-7
Steel 1.0254
Stainless steel 1.4301
PN-EN1563: 2012
PN-EN 1,503-3:2003
PN-EN 10088-1:2014
4 Seat Brass PN-EN 1982:2010
5Poppet Cast-iron, EN-GJS 400-15 EN-GJS500-7
EPDM
PN-EN1563:2012
PN-ISO1629:2005
6Cap Cast-iron, EN-GJS 400-15
EN-GJS500-7 PN-EN1563: 2012
7Stem Stainless steel 1.4021 PN-EN 10088-1: 2014
8Spindle Stainless steel 1.4301 PN-EN 10088-1:2014
9Saddle tee Aluminium, AlSi PN-EN 1706:2011
10 Coupling Cast-iron, EN-GJS 400-15
EN-GJS500-7 PN-EN1563: 2012
11 Lower body Cast-iron, EN-GJS 400-15
EN-GJS500-7 PN-EN1563: 2012
12 Lower flange Cast-iron, EN-GJS 400-15
EN-GJS500-7 PN-EN1563: 2012
13 Stopper Brass PN-EN 1982:2010
14 Stem nut Brass PN-EN 1982:2010
15 O-ring EPDM PN-ISO 1629:2005
16 Bolt Stainless steel, A2 PN-EN ISO 4017: 2011
PN-EN ISO 4762: 2006
17 Nut Stainless steel, A4 PN-EN ISO 4032: 2013
18 Ball Cellular polypropylene or aluminium
alloy AlSi/EPDM PN-EN 1706:2011 PN-ISO 1629:2005
19 Drainage Polypropylene PP PN-EN ISO 1873-1:2000

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2.3 DIMENSIONS DN80
DN RD L H H
1
H
2
H
3
Weight
[kg]
1250 1890 2055 1130 75
1500 2140 2305 1380 81
1800 2440 2605 1680 89
80 600 110
[mm]

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2.4 MATERIALS DN100
List of basic materials used for the construction of an overground hydrant TYPE 8003 DN100 —
see table
Item
Part name Material Reference standard
1Main body Cast-iron, EN-GJS 400-15
EN-GJS500-7 PN-EN1563: 2012
2 Lower body Cast-iron, EN-GJS 400-15
EN-GJS500-7 PN-EN1563: 2012
3Column
Cast-iron, EN-GJS 400-15
EN-GJS500-7
Steel 1.0254
Stainless steel 1.4301
PN-EN1563: 2012
PN-EN 1,503-3:2003
PN-EN 10088-1:2014
4 Sleeve Brass PN-EN 1982:2010
5Poppet Cast-iron, EN-GJS 400-15 EN-GJS500-7
EPDM
PN-EN1563:2012
PN-ISO1629:2005
6Cap Cast-iron, EN-GJS 400-15
EN-GJS500-7 PN-EN1563: 2012
7Stem Stainless steel 1.4021 PN-EN 10088-1: 2014
8Spindle Stainless steel 1.4301 PN-EN 10088-1:2014
9Saddle tee Aluminium, AlSi PN-EN 1706:2011
10 Coupling Cast-iron, EN-GJS 400-15
EN-GJS500-7 PN-EN1563: 2012
11 Rotary clamp Cast-iron, EN-GJS 400-15
EN-GJS500-7 PN-EN1563: 2012
12 Rotary flange Cast-iron, EN-GJS 400-15
EN-GJS500-7 PN-EN1563: 2012
13 Stopper Brass PN-EN 1982:2010
14 Stem nut Brass PN-EN 1982:2010
15 O-ring EPDM PN-ISO 1629:2005
16 Bolt Stainless steel, A2 PN-EN ISO 4017: 2011
PN-EN ISO 4762: 2006
17 Nut Stainless steel, A4 PN-EN ISO 4032: 2013
18 Ball Cellular polypropylene or aluminium
alloy AlSi/EPDM PN-EN 1706:2011 PN-ISO 1629:2005
19 Drainage Polypropylene PP PN-EN ISO 1873-1:2000

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2.5 DIMENSIONS DN100
DN RD L H H
1
H
2
H
3
Weight
[kg]
1250 1890 2075 1125 85
1500 2140 2325 1375 90
1800 2440 2625 1675 96
100 600 110
[mm]

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2.6 STANDARDS
PN-EN 1074-1: 2002 Valves for water supply. Fitness for purpose requirements and appropriate
verification tests. General requirements
PN-EN 1074-6: 2009 Valves for water supply. Fitness for purpose requirements and appropriate
verification tests. Hydrants.
PN-89/H-02650 Fittings and pipelines. Pressures and temperatures.
PN-EN 19:2005 Industrial valves. Marking of metallic valves.
PN-EN 1092-2: 1999 Flanges and their connections. Circular flanges for pipes,
valves, fittings and accessories, PN designated. Cast iron flanges.
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-EN1563: 2012 Founding. Spheroidal graphite cast irons.
PN-EN1370: 2012 Founding. Examination of surface condition by
visual-tactile comparators.
PN-EN14384: 2009 Standpost hydrants.
PN-EN 10088-1: 2014 Stainless steels. List of stainless steels.
PN-89/H-84023/07 Specific application steel. Pipe steel. Grades.
PN-EN 1706 2011 Aluminium and aluminium alloys. Foundings. Chemical composition and
mechanical properties.
PN-EN1982: 2010 Copper and copper alloys. Ingots and castings.
PN-EN12420: 2002 Copper and copper alloys. Forgings.
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 ISO 4762:2006 Hexagon socket headcap screws.
PN-EN ISO 4017:2011 Hexagon head screws.
Product grades A and B.
PN-EN ISO 4014:2011 Hex head bolt. Product grades A and B.
PN-EN ISO 4032:2013 Hexagon regular nuts (style 1). Product grades A and B.
PN-EN ISO 7091:2003 Plain washers. Normal series. Product grade C
PN-77/M-82008 Spring washers.
PN-EN ISO 8752:2009 Spring-type straight pins. Slotted, heavy duty.
PN-69/M-80202 Steel wires 1x7.
BN-89/8511-15 Metallic seals.
PN-ISO 1629: 2005 Rubbers and lattices. Nomenclature.
PN-EN ISO 1873-1: 2000 Plastic materials. Polypropylene (PP) moulding and extrusion materials.
Designation system and basis for specifications.
PN-EN ISO 1872-1:2000 Plastic materials. Polyethylene (PE) moulding and extrusion materials.
Designation system and basis for specifications.
PN-EN ISO 12944-5: 2009 Paints and varnishes. Anti-corrosion protection of steel structures by means of
protective painting systems. Protective paint systems.
2.7 ORDERING REGULATIONS
Above-ground fire hydrants are specific purpose industrial valves, therefore orders must include:
- product's catalogue number,
- intended use, e.g. for fire 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 1563: 2012
- max. operating temperature — acc. to PN-89/H — 02650.
2.8 MANUFACTURE AND ACCEPTANCE

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The above-round hydrants are accepted and produced in accordance with: PN-EN 1074-6:2009 (Valves for
water supply. Fitness for purpose requirements and appropriate verification tests. Hydrants.) and PN-EN
14384:2009
(Above-ground fire hydrants.) All hydrants (100%) are subject to tightness testing. The tests include external
body tightness and closing tightness.
2.9 MARKINGS
The above-ground hydrants are marked in accordance with: PN-EN-19: 2005, PN-EN-1074-6: 2009
markings on the front and back walls of the body chamber. The marking contains the following data:
- nominal diameter
- nominal pressure
- type of body material
- manufacturer trade mark
- direction of medium flow.
The location on the valve specified in the documentation features the nameplate which contains the
following data: - manufacturer's company name and logo
- product 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 and column pipes are protected with electro-deposited epoxy coat. The
coat has been approved for contact with foodstuffs.
The anti-corrosion coating layer minimum thickness is 250µm with UV protection.
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 fastening bolts for external hydrant's part, if other than stainless steel grade 1.4301, should
have corrosion protection in the form of coat, e.g. Fe/Zn5.
3.2 PACKAGING
The hydrants are placed in plastic film sleeves and additionally wrapped with stretch wrap when placed on
pallets.
3.3 STORAGE
Store the hydrants in sheltered rooms.

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3.4 TRANSPORT
Transport the hydrants on sheltered vehicles.
DN80 DN100
4 ASSEMBLY AND INSTALLATION
4.1 INSTALLATION GUIDELINES
Above-ground fire hydrants TYPE 8003 may be installed on underground pipelines in case of horizontal
systems. The products described herein are designed for installation using flange on the pipeline acting as
medium (water) supply. The hydrant is equipped with special flanges to enable free above-ground part's rotation
(from 0
ο
to 360
ο
). Special bolts for connecting the lower part with the above-ground part, if they have been
loosened to enable rotation shall be tightened with max. torque 35Nm. Note that the system must not expose the
hydrant to bending or tensile stress from loading with the unsupported pipeline sections. A hydrant assembled
and adjusted by the manufacturer is ready for installation in the system. Any dismantling of the hydrant
components may result in loss of tightness.

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4.2 INSTALLATION INSTRUCTIONS
Before installing the hydrants, check the technical and commercial documentation, i.e. application for
media and operation parameters of the pipeline, in which they are to be installed.
Note! If the product is damaged mechanically, do not install it in the pipeline.
Any change in the operating conditions must be consulted with the hydrant's manufacturer beforehand.
1. Hydrant; 2. Pipeline connection flange; 3. Gasket; 4. Nut; 5. Fastening bolt

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4.3 OPERATION
The outdoor hydrants are designed for drawing fire fighting water. Detailed requirements are given in
applicable regulations defining the need for fire fighting water. The diagram above shows an example installation
method for an above-ground hydrant, the installation method largely depends on the applied rules based on the
local climate and geologic conditions.
Exceeding the operating limits of the fitting may result in damage that will not be covered by the suretyship
granted by the manufacturer.
It is recommended to change the hydrant's settings once a year.
4.4 OH&S REGULATIONS
In case of hydrants, guidelines and recommendations for installation of water systems and devices
installed in water supply stations and other facilities apply.
Misuse of this product is prohibited.
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.