Operation and maintenance

manual for

FLANGED
GATE VALVES
WITH SOFT SEALS

P/N
2112

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.

OPERATION AND MAINTENANCE MANUAL 12-2016

 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 .............................................................................................................................................. 5
2.4 REFERENCE STANDARDS ....................................................................................................................... 6
2.5 ORDERING INFORMATION ..................................................................................................................... 6
2.6 PRODUCTION 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 TRANSPORT ............................................................................................................................................... 8
4 ASSEMBLY AND INSTALLATION ................................................................................................................. 8
4.1 ASSEMBLY GUIDELINES ......................................................................................................................... 8
4.2 ASSEMBLY INSTRUCTIONS .................................................................................................................... 9
4.3 OPERATION ................................................................................................................................................ 9
4.4 OCCUPATIONAL HEALTH AND SAFETY ............................................................................................. 9
5 WARRANTY TERMS AND CONDITIONS...................................................................................................... 9

OPERATION AND MAINTENANCE MANUAL 12-2016 2

 1 TECHNICAL DESCRIPTION

1.1 PRODUCT DESIGNATION AND IDENTIFICATION

The subject of this Operation and Maintenance Manual is:

Type 2112 flanged cast iron wedge gate valve, with the installation length according
to BS 5163-1
- full smooth walled bore design
- wedge (closure) embedded in 100% pure elastomer
- non-rising spindle
- stem head-type seal in valve cover (O-rings)

1.2 USE

The gate valves with soft seals are intended for water supply systems, especially for potable water,
sewage systems, and industrial processing systems. The valves are intended for surface and underground
systems and must be installed in horizontal pipelines.

1.3 TECHNICAL SPECIFICATION

The gate valves with soft seals are intended for transporting potable or industrial water and other
liquids (if approved by the manufacturer).

- temperature range: -10°C to +70°C

- nominal diameter range: DN40 – DN300 [mm]
- Maximum medium flow rate: - liquid: max. 4 [m/s]
- gas: max. 30 [m/s]

- The driving torque at opening start and closing end is as listed below:

DN [mm] 40 50 65 80 100 125 150 200 250 300

Mmax [Nm] 55 80 100 200

• Valve control mode: the standard version of gate valve has the
clockwise closing sense of rotation.
The closing sense of rotation can be opposite on special order.
• The valve connection flange design is acc. to EN 1092-2
• with the sizes compliant with the nominal pressure values.
- The installation length and its tolerance is acc. to EN 558 Series 3 - TYPE 2112

• Nominal pressure PN values: 0.6 MPa

1.0 MPa
1.6 MPa

2 DESIGN

2.1 DESCRIPTION OF THE VALVE DESIGN

Type 2112 gate valves with soft seals manufactured by F.A. „JAFAR”S.A. feature a smooth walled bore, a
non-ring spindle, and an o-ring spindle seal installed in a head-type valve cover. The stem is guided by a bushing
in the valve cover neck and a sealing plug. The stem seal is provided by the plug sealing assembly, which is a
system of O-rings. The gate valve closure is a cast iron wedge completely coated with rubber and featuring a
stem nut located on the wedge lug. The stem is equipped with an interlocking collar installed by necking. From
the bottom the stem collar rests on a seat in the head via a bushing which acts as a sealed bearing. The plug over
the flange is secured against loosening with a wire spring ring. The valve cover to body joints is made with hex

OPERATION AND MAINTENANCE MANUAL 12-2016 3

cap screws mounted flush with the valve cover and preserved with a paraffin compound. The valve cover to body
seal is a rubber gasket which also seals the bolt penetration points to prevent any leaks from their leads. All inner
and outer cast-iron surfaces of the valve are epoxy powder coated. The stem may be operated manually using a
hand wheel or, in case of gate valves located underground, through a hood and gate valve casing, using a T
socket.

2.2 MATERIALS

The table below lists the structural materials of the gate valves with soft seals.

Item Part designation Material Reference standard

1 Body EN-GJS 400-15 cast iron EN 1563

2 Cover EN-GJS 400-15 cast iron EN 1563

EN-GJS 400-15 cast iron EN 1563

3 Wedge
Rubber: EPDM (or NBR) ISO 1629

4 Skid Polyamide EN ISO 1874-1

5 Sealing plug Brass EN 1982

6 Safety ring Steel grade 1.1260 74/H-84032

7 Cleaning seal Rubber: EPDM (or NBR) ISO 1629

8 Spindle nut Brass EN 1982

9 Spindle Steel grade 1.4021 EN 10088-1

10 Valve cover gasket Rubber: EPDM (or NBR) ISO 1629

11
O-ring seal Rubber: EPDM (or NBR) ISO 1629
12

Bolt, cap,
13 Acc. to reference standards EN ISO 4762
hex

acc. to manufacturer's
14 Bolt plug Paraffin
Technical Guidelines

15 Washer Polyamide PA6 EN ISO 1874-1

OPERATION AND MAINTENANCE MANUAL 12-2016 4

 2.3 DIMENSIONS

No. of
K l n
DN L H d D C f S turns for Mass
PN16 (PN10) PN16 (PN10) PN16 (PN10)
opening
[mm] - [mm] [kg]
40 165 220 84 150 110 19 16 3 4 14 11 8,5
50 178 230 99 165 125 19 19 3 4 14 13,5 10,5
65 190 265 118 185 145 19 19 3 4 17 14 15,0
80 203 290 132 200 160 19 19 3 8 17 17 19,5
100 229 325 156 220 180 19 19 3 8 19 21 26,0
125 254 365 184 250 210 19 19 3 8 19 26 33,5
150 267 457 211 285 240 23 20 3 8 19 26 48,2
200 292 534 266 340 295 23 22 3 12 (8) 24 34,5 73,3
250 330 633 319 405 355 (350) 28 (23) 25 3 12 27 42,5 97,0
300 356 708 370 460 410 (400) 28 (23) 27 4 12 27 51 134,5

OPERATION AND MAINTENANCE MANUAL 12-2016 5

 2.4 REFERENCE STANDARDS

EN 1074-1 Valves for water supply. Fitness for purpose requirements and appropriate
verification tests. General requirements
EN 1074-2 Valves for water supply. Fitness for purpose requirements and appropriate
verification tests. Isolating valves.
89/H-02650 Valves and pipelines. Pressure and temperature ratings.
EN 1092-2 Flanges and their joints. Circular flanges for pipes,
valves, fittings and accessories, PN designated. Cast iron flanges.
EN19 Industrial valves. Marking of metallic valves
EN 12266-1 Industrial valves. Testing of metallic valves. Pressure tests, test procedures
and acceptance criteria.
Mandatory requirements.
EN 558 Industrial valves. Face-to-face and centre-to-face dimensions of metal valves
for use in flanged pipe systems. PN-designated valves.
EN ISO 6708 Pipework components. Definition and selection of DN (nominal size).
EN 1559-1 Founding. Technical conditions of delivery. General.
EN 1561 Founding. Grey cast irons.
EN 1563 Founding. Spheroidal graphite cast irons.
EN 1370 Founding. Surface roughness inspection by
visual tactile comparators.
EN 10088-1 Stainless steels. List of stainless steels.
74/H-84032 Spring steel. Grades.
EN 1982 Copper and copper alloys. Ingots and castings.
EN 12420 Copper and copper alloys. Forgings.
ISO 965-1 General purpose ISO metric threads. Tolerances. Principles and basic data.
ISO 2903 Trapezoid ISO metric threads. Tolerances.
EN ISO 4762 Hexagon socket head cap screws.
EN 10204 Metallic products. Types of inspection documents.
ISO 1629 Rubbers and latices. Nomenclature.
EN ISO 1872-1 Plastics. Polyethylene (PE) moulding and extrusion materials. Designation
system and basis for specifications.
EN ISO 1873-1 Plastics. Polypropylene (PP) moulding and extrusion materials. Designation
system and basis for specifications.
EN ISO 1874-1 Plastics. Polyamide (PA) moulding and extrusion materials. Designation
system and basis for specification.
EN ISO 12944-5 Paints and varnishes. Corrosion protection of steel structures by protective
paint systems. Protective painting 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 water supply systems,
and:
- nominal diameter, acc. to EN ISO 6708
- nominal pressure, acc. to 89/H-02650;
- type of body material — acc. to EN 1561 or EN 1563
- maximum operating temperature, acc. to 89/H-02650.

OPERATION AND MAINTENANCE MANUAL 12-2016 6

 2.6 PRODUCTION AND ACCEPTANCE

Type 2112 gate valves are accepted and produced

in accordance with EN 1074-2 (Valves for water supply. Fitness for purpose requirements and appropriate
verification tests. Isolating valves) and EN 12266-1 (Industrial valves. Testing of valves). All valves (100%) are
subject to tightness testing. The tests include external body tightness and closing tightness.

2.7 MARKINGS

The gate valve marking meets the following standards: EN-19, EN-1074-1.

The gate valve bodies feature markings on the front and back walls of the body chamber. The marking
contains the following data:
- valve type (defined by the product reference standard number)
- nominal diameter
- nominal pressure
- body material type
- manufacturer trademark
The location on the valve specified in the documentation features the nameplate which contains the
following data: - manufacturer's company name and logo
- 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 inner and outer cast-iron surfaces 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.
The casting surface is pre-treated for epoxy coating in accordance with the relevant technical documentation and
EN ISO 12944-5.
The screws connecting the body and the cover are manufactured as stainless, grade OH18N9 or Fe/Zn5
(galvanised steel).

3.2 PACKAGING

The gate valves are packed on EURO pallets (1200x800) and protected with heat-shrunk film.

3.3 STORAGE

Store the gate valves in sheltered rooms.

OPERATION AND MAINTENANCE MANUAL 12-2016 7

 3.4 TRANSPORT

Transport the gate valves on sheltered vehicles.

The DN65 to DN300 gate valves with soft seals shall be handled and installed on belt slings (see the example
diagram below) and secured from turning.

4 ASSEMBLY AND INSTALLATION

4.1 ASSEMBLY GUIDELINES

The Type 2112 flanged cast iron gate valves can be installed in underground or overground pipelines
both in horizontal or vertical orientation. The listed products are suitable for joining with the flanged ends of
pipelines with the size equal to that of the valve flanges. Note that the system must not expose the (gate) valve to
bending or tensile stress from loading with the weight of unsupported pipeline sections. It is recommended to
perform installation works considering pipeline compensation due to temperature and pressure. The valve
assembled and adjusted by the manufacturer is ready for installation. Any dismantling of the valve components
may result in loss of seal.

OPERATION AND MAINTENANCE MANUAL 12-2016 8

 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, remove the main bore plugs, check the inner surfaces of the
valve and thoroughly flush with water, if necessary.
CAUTION! If the product is damaged mechanically, do not install it in the pipeline.

The figure below shows the method for coupling the gate valve and the valve orientation diagrams:

Recommend Permitted
ed

Not permitted

1. Valve; 2. Nut; 3. Gasket; 4. Pipeline flange; 5. Washer; 6. Fastening bolt

4.3 OPERATION

The gate valve shall be operated according to all relevant requirements for cut-off valves, i.e. either in fully
open or fully closed positions. Leaving the gate valve partially opened (or closed) may result in seal failure. To
ensure full performance, switch the gate valve periodically (once a year, from fully open to fully closed).
Exceeding the operating limits of the valve may result in damage that will not covered by the suretyship
granted by the manufacturer.

4.4 OCCUPATIONAL HEALTH AND SAFETY

The valves with soft seals 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

The product assembled, installed and operated in compliance with this Manual is covered by a
commercial warranty from the manufacturer. The conditions and period of the warranty is specified in the
warranty sheet.

OPERATION AND MAINTENANCE MANUAL 12-2016 9