Jafar 2109 Operation And Maintenance Manual

Operation and maintenance
manual for
METAL SEATED
GLAND PACKED
FLANGED
GATE VALVES
P/N
2109
2909
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
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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 .............................................................................................................................................. 5
2.4 REFERENCE STANDARDS ....................................................................................................................... 6
2.5 ORDERING INFORMATION ..................................................................................................................... 7
2.7 MARKINGS ................................................................................................................................................. 7
3 PROTECTION, STORAGE & TRANSPORT .................................................................................................... 7
3.1 PROTECTIVE COATINGS ......................................................................................................................... 7
3.2 PACKAGING ............................................................................................................................................... 7
3.3 STORAGE .................................................................................................................................................... 8
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
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1 TECHNICAL DESCRIPTION
1.1 PRODUCT DESIGNATION AND IDENTIFICATION
The subject of this Operation and Maintenance Manual is:
TYPE 2109 and 2909 metal seated gland packed wedge gate valve
- bore with recess underneath the wedge
- wedge (closure) with metal sealing rings made
of non-ferrous material or stainless steel
- non-rising spindle
- stem sealed with braided gland packing
1.2 USE
The TYPE 2109 and 2909 metal seated braced stem wedge gate valves are intended for industrial
systems, heating systems, air systems for petroleum products and other chemically inert liquids. The valves
are intended for overground and underground installations and must be installed horizontal pipelines in
industrial systems.
1.3 TECHNICAL SPECIFICATION
The metal seated gland packed wedge gate valves with hard seals are intended for transporting of the
specified media and other liquids as agreed with the manufacturer.
- Temperature: -10°C to +150°C
- up to 120°C with bronze rings
- up to 150ºC with steel rings
- Nominal diameter (dimension) range: DN40 to DN600 [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]
Mmax [Nm]
40
50
55
65
80
80
100
125
150
100
200
250 300
200
350 400
300
500 600
400
- Valve control mode: the standard version of gate 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 PN-EN 1092-2: 1999
with the sizes compliant with the nominal pressure values.
- the connection flanges are manufactured to PN-EN ISO 2285210:2011
- Valve drive coupling type: B3
- - Installation length: PN-EN 558-1: 2012
Series 14.
-
Nominal pressure PN values:
- 1.0 MPa
- 1.6 MPa
2 DESIGN
2.1 DESCRIPTION OF THE VALVE DESIGN
The TYPE 2109 and 2909 metal seated gland packed wedge gate valves manufactured by F.A. JAFAR S.A.
feature a bore with a recess underneath the wedge, a non-rising stem, and an O-ring stem seal installed in the
valve cover. The stem seal is made as a sealing assembly with five (5) braided gland packings. The gate valve
closure is a metallic seals (with rings pressed into the wedge and the valve body seat) with the replaceable spindle
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nut on the wedge lug. The top section of the valve cover is the gland packing unit which keeps the flow control
head sealed. The gate valve stem is a cylindrical shaft tipped with a trapezoid thread at the bottom, which is the
drive section, whereas the top tip is designed to match the control element. The valve cover is bolted tight to the
valve body. The valve cover to body seal is an asbestos-free formed gasket. All inner and outer cast-iron surfaces
of the valve are polyvinyl coated. The type 2109 spindle is driven with a hand wheel, and the type 2909 valve is
switched with a drive actuator.
2.2 MATERIALS
The table below lists the structural materials of the metal seated gland packed wedge gate valves with soft
seals.
Item Part designation
1
Body
2
Cover
3
Wedge
4
Packing gland
5
Spindle
6
Gland
7
Spindle nut
8
Seal
Material
Spheroidal cast-iron, EN-GJS 400-15,
EN-GJS 500-7
Spheroidal cast-iron, EN-GJS 400-15,
EN-GJS 500-7
Spheroidal cast-iron, EN-GJS 400-15,
EN-GJS 500-7
Spheroidal cast-iron, EN-GJS 400-15,
EN-GJS 500-7
Steel grade 1.4021
Reference standard
PN-EN 1563: 2012
PN-EN 1563: 2012
PN-EN 1563: 2012
PN-EN 1563: 2012
PN-EN 10088-1: 2014
Spheroidal cast-iron, EN-GJS 400-15,
EN-GJS 500-7
Spheroidal cast-iron, EN-GJS 400-15,
EN-GJS 500-7
Carbon seal, DN40-DN300: PTFE +
carbon; DN350 DN600
PN-EN 1563: 2012
PN-EN 1563: 2012
acc. to manufacturer's
Technical Guidelines
9
O-ring seal
Steel grade 1.4021
PN-EN 10088-1: 2014
10
Handwheel
Grey cast iron, EN-GJS 250
PN-EN 1561: 2012
Valve cover gasket
Asbestos-free carbon gasket, DN40DN300; AF300 – DN350-DN600
Steel, 1.0038 – DN40-DN300: Fe/Zn5
– DN350-DN600
Steel, 1.0038 – DN40-DN300: Fe/Zn5
– DN350-DN600
acc. to manufacturer's
Technical Guidelines
PN-EN ISO 4017:2011
11
12
13
Bolt
Nut
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PN-EN ISO 4032:2013
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2.3 DIMENSIONS
Drive-ready: 2109
With electric drive actuator: 2909
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D
PN16
(PN10)
PN16 (PN10)
PN16 (PN10)
none
84
99
118
132
156
184
211
266
319
370
[mm]
150
165
185
200
220
250
285
340
405 (395)
460 (445)
1033
429
H1
d
PN
L
H
[mm] [bar]
40
50
65
80
100
125
150
200
250
300
140
150
170
180
190
200
210
230
250
270
245
255
277
303
340
387
454
538
629
730
350
290
860
400
500
600
310
350
390
935 1370
480
1135 1555 609 (582)
1305 1650 720 (682)
PN10/16
DN
K
l
C
f
110
125
145
160
180
210
240
295
355 (350)
410 (400)
19
19
19
19
19
19
19
20
22
25
3
3
3
3
3
3
3
3
3
4
19
19
19
19
19
19
23
23
28 (23)
28 (23)
4
4
4
8
8
8
8
12
12
12
520 (505)
470 (460)
27
4
28 (23)
580 (565)
715 (670)
840 (780)
525 (515)
650 (620)
770 (725)
28
32
36
4
4
5
31 (28)
34 (28)
37 (31)
PN16 (PN10)
n
d1
d2
d3
d4
Drive
No.
of
turn
Tr12X3
Tr12X3
Tr16X4
Tr16X4
Tr20X4
Tr20X4
Tr22X5
Tr22X5
Tr26X5
Tr28X5
none
15
18
20
26
30
29
36
46
48
57
320
Tr32X6
SA 14.2
F14
65
320
630
630
Tr32X6
Tr40X6
Tr40X6
SA 14.6
F14
74
91
108
Dk
LH thread
160
160
160
160
200
200
200
250
250
320
16
16 175 140 30 18x4
20
20
[mm]
-
none
2.4 REFERENCE STANDARDS
PN-EN 1074-1: 2002
PN-EN 1074-2: 2002
PN-EN 1171: 2007
PN-89/H-02650
PN-EN 1092-2: 1999
PN-EN19: 2005
PN-EN 12266-1: 2012
PN-EN 558: 2012
PN-EN ISO 6708: 1998
PN-EN 1559-1: 2011
PN-EN 1561: 2012
PN-EN 1563: 2012
PN-EN 1370: 2012
PN-EN 10088-1: 2014
PN-74/H-84032
PN-EN 1982: 2010
PN-EN 12420: 2002
PN-ISO 965-1: 2001
PN-ISO 2903: 1996
PN-EN ISO 4762: 2006
PN-EN 10204: 2006
PN-ISO 1629: 2005
PN-EN ISO 1872-1: 2000
PN-EN ISO 1873-1: 2000
PN-EN ISO 1874-1: 2010
PN-EN ISO 12944-5: 2009
Valves for water supply. Fitness for purpose requirements and appropriate
verification tests. General requirements
Valves for water supply. Fitness for purpose requirements and appropriate
verification tests. Isolating valves.
Industrial valves. Cast iron gate valves.
Valves and pipelines. Pressure and temperature ratings.
Flanges and their joints. Circular flanges for pipes,
valves, fittings and accessories, PN designated. Cast iron flanges.
Industrial valves. Marking of metallic valves
Industrial valves. Testing of metallic valves. Pressure tests, test procedures
and acceptance criteria. Mandatory requirements.
Industrial valves. Face-to-face and centre-to-face dimensions of metal valves
for use in flanged pipe systems. PN-designated valves.
Pipework components. Definition and selection of DN (nominal size).
Founding. Technical conditions of delivery. General.
Founding. Grey cast irons.
Founding. Spheroidal graphite cast irons.
Founding. Surface roughness inspection by
visual tactile comparators.
Stainless steels. List of stainless steels.
Spring steel. Grades.
Copper and copper alloys. Ingots and castings.
Copper and copper alloys. Forgings.
General purpose ISO metric threads. Tolerances. Principles and basic data.
Trapezoid ISO metric threads. Tolerances.
Hexagon socket head cap screws.
Metallic products. Types of inspection documents.
Rubbers and latices. Nomenclature.
Plastics. Polyethylene (PE) moulding and extrusion materials. Designation
system and basis for specifications.
Plastics. Polypropylene (PP) moulding and extrusion materials. Designation
system and basis for specifications.
Plastics. Polyamide (PA) moulding and extrusion materials. Designation
system and basis for specification.
Paints and varnishes. Corrosion protection of steel structures by protective
paint systems. Protective painting systems.
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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 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
- maximum operating temperature, acc. to PN-89/H-02650.
2.6 PRODUCTION AND ACCEPTANCE
TYPE 2109 and TYPE 2909 metal seated gland packed gate valves are accepted and produced in
accordance with: PN-EN 1074-2: 2002 (Valves for water supply. Fitness for purpose requirements and
appropriate verification tests. Isolating valves) and PN-EN 12266-1: 2012 (Industrial valves. Testing of valves).
All gate valves are leak tested (100%). The tests include external body tightness and closing tightness.
2.7 MARKINGS
The gate valve marking meets the following standards: PN-EN-19: 2005, PN-EN-1171: 2007.
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 grey polyvinyl coat.
The anti-corrosion coating layer minimum thickness is 100µm.
The casting surface is pre-treated for polyvinyl coating in accordance with the relevant technical documentation
and PN-EN ISO 12944-5: 2009.
The screws connecting the body and the cover are manufactured as stainless, grade 1.4301 or Fe/Zn5 (galvanised
steel).
3.2 PACKAGING
The gate valves are packed on EURO pallets (1200x800) and protected with heat-shrunk film.
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3.3 STORAGE
Store the gate valves in sheltered rooms.
3.4 TRANSPORT
Transport the gate valves on sheltered vehicles.
Never suspend the valve by its drive actuator when handling.
It is recommended use belt slings as shown in the diagram above
for handling and installation of the gate valves from DN50 to DN200.
4 ASSEMBLY AND INSTALLATION
4.1 ASSEMBLY GUIDELINES
The Type 2109 and 2909 metal seated gland packed wedge 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.
Assemble with consideration to pressure and temperature compensation of the pipeline. The valve assembled and
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adjusted by the manufacturer is ready for installation. Any dismantling of the valve components may result in loss
of seal.
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
ed
Permitted
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 knife 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 metal seated gland packed flanged gate 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 conditions and period of the warranty is specified in the
warranty sheet.
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