OPERATING AND MAINTENANCE MANUAL 12-2016
Operation
and Maintenance Manual
GATE VALVES WITH SOFT SEALS WITH THREADED
CONNECTIONS
Cat. no.
3116
3126
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 DESIGN ............................................................................................................................................................... 3
2.1 FITTING DESIGN DESCRIPTION ............................................................................................................. 3
2.2 MATERIALS ................................................................................................................................................ 4
2.3 DIMENSIONS .............................................................................................................................................. 5
2.4 STANDARDS ............................................................................................................................................... 6
2.5 ORDERING REGULATIONS ..................................................................................................................... 6
2.6 MANUFACTURE AND ACCEPTANCE .................................................................................................... 7
2.7 MARKING .................................................................................................................................................... 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 INSTALLATION GUIDELINES ................................................................................................................. 8
4.2 INSTALLATION INSTRUCTIONS ............................................................................................................ 8
4.3 OPERATION ................................................................................................................................................ 9
4.4 OH&S REGULATIONS ............................................................................................................................... 9
5 GUARANTEE CONDITIONS ............................................................................................................................ 9
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1 TECHNICAL DESCRIPTION
1.1 PRODUCT NAME AND FEATURES
The subject of this O&MM is:
Type 3116 and 3126 cast iron threaded gate valves with soft seals.
- 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 PURPOSE
The Type 3116 and 3126 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 threaded 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: DN25 – DN50 [mm],
- maximum medium flow rate: - liquid: max. 4 [m/s]
- gas: max. 30 [m/s]
- driving torque at opening start and closing end are listed below:
DN [mm]
25 32 40 50
Mmax [Nm]
25 55
- fitting actuation: in the basic version, the direction of damper closing is clockwise (to the right)
upon special request the closing direction may be opposite.
- the valve connection thread design is acc. to EN 10226-1
normal product grade [A].
- 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
TYPE 3116 and TYPE 3126 threaded gate valves with soft seals manufactured by F.A. “JAFAR” S. A.
feature a smooth walled bore, a non-rising stem, 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 (for DN40 and DN50 sizes). 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. In case of sizes DN25 and DN32 the stem is solid and is not fitted with a
bearing in the form of a sealing bushing but the wedge insert consists of a brass forging with thread. The plug is
secured against unscrewing using a spring wire ring installed above the flange. The valve cover to body joint is
made with hexagon socket head cap screws mounted flush with the valve cover and secured with paraffin
compound. The valve cover to body seal is a rubber gasket which also seals the bolts to prevent any leaks from
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their openings. All inner and outer cast-iron surfaces of the gate 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
This table lists the materials used in the construction of gate valves with soft seals.
Item Part name Material Reference standard
1 Body
EN-GJS 400-15 cast iron
EN 1563
2 Cover EN-GJS 400-15 cast iron EN 1563
3 Wedge
Brass (DN25-DN32)
Cast iron (DN40-DN50)
EN-GJS 400-15, EN-GJS 500-7
Rubber: EPDM (or NBR)
EN 1982
EN 1563
ISO 1629
4 Skid Polyamide EN ISO 1874-1
5 Sealing plug Brass EN 1982
6 Locking ring Steel 1.1260 74/H-84032
7 Cleaning seal Rubber: EPDM (or NBR) ISO 1629
8 Stem nut Brass EN 1982
9 Stem Steel 1.4021 EN 10088-1
10 Valve cover gasket Rubber: EPDM (or NBR) ISO 1629
11
12
O-ring seal
Rubber: EPDM (or NBR) ISO 1629
13
Hexagon socket head
cap screws
Acc. to reference standards EN ISO 4762
14 Bolt plug Paraffin
acc. to manufacturer's
technical guidelines
15 Washer Polyamide PA6 EN ISO 1874-1
16 Pipe gasket Rubber: EPDM (or NBR) ISO 1629
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2.3 DIMENSIONS
TYPE 3116 DN40-DN50 TYPE 3126 DN40-DN50
TYPE 3116 DN25-DN32 TYPE 3126 DN25-DN32
[mm] [inch] 3116 [kg] 3126 [kg]
25 1" / 1" 105 2,6 2,6
5/4" / 5/4" 120 2,9 2,8
5/4" / 2" 130 - 2,7
6/4" / 6/4" 6,1 5,6
6/4" / 2" - 5,8
50 2" / 2" 200 40 40 225 6,9 6,6
Weight
12
40 40 215
14
[mm]
S
32
40 180
25 40 160
DN HG / R L m
m
1
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2.4 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 Fittings and pipelines. Pressures and temperatures for
fittings, connectors and equipment with PN markings. Cast iron flanges.
EN19 Industrial fittings. Metal fitting marking.
EN 12266-1 Industrial valves. Testing of metallic valves. Pressure tests, test procedures
and acceptance criteria.
Mandatory requirements.
EN ISO 6708 Definition and selection of the DN /nominal dimension/
EN 10226-1 Pipe threads where pressure tight joints are made on the threads - Part 1:
Taper external threads and parallel internal threads.
Dimensions, tolerances and designation
ISO 965-1 ISO general purpose metric screw threads. Tolerances. Principles and basic
data.
ISO 2903 Trapezoid ISO metric threads. Tolerances.
EN 1982 Copper and copper alloys. Ingots and castings.
EN 12420 Copper and copper alloys. Forgings.
EN 1559-1 Founding. Technical conditions of delivery. General.
EN 1563 Founding. Spheroidal graphite cast irons.
EN 1370 Founding. Examination of surface condition by
visual-tactile comparators.
EN 10088-1 Stainless steels. Grades of stainless steel.
74/H-84032 Spring steel. Grades.
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 Plastic materials. Polyethylene (PE) moulding and extrusion materials.
Designation system and basis for specifications.
EN ISO 1873-1 Plastic materials. Polypropylene (PP) moulding and extrusion materials.
Designation system and basis for specifications.
EN ISO 1874-1 Plastic materials. Polyamide (PA) forming and extrusion moulding materials.
Designation system and basis for specification.
EN ISO 12944-5 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 EN ISO 6708
- nominal pressure, acc. to 89/H-02650;
- type of body material — acc. to EN 1561 or EN 1563
- max. operating temperature — acc. to 89/H — 02650.
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2.6 MANUFACTURE AND ACCEPTANCE
TYPE 3116 and TYPE 3126 gate valves with soft seals 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 metallic valves). All gate valves are leak tested (100%).
The tests include external body tightness and closing tightness.
2.7 MARKING
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 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 EN ISO 12944-5.
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.
3.3 STORAGE
Store the gate valves in sheltered rooms.
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3.4 TRANSPORT
Transport the gate valves using sheltered vehicles.
4 ASSEMBLY AND INSTALLATION
4.1 INSTALLATION GUIDELINES
The TYPE 3116 and TYPE 3126 threaded gate valves with soft seals can be installed in underground or
surface pipelines both in horizontal or vertical orientation. The listed products are suitable for joining with
threaded ends of pipelines with (thread) size equal to that of the valve threads. 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 gate valve
assembled and adjusted by the manufacturer is ready for installation. Any dismantling of the valve components
may result in loss of tightness.
4.2 INSTALLATION INSTRUCTIONS
Before attempting to install the fitting, check the technical and commercial documents delivered with the
product to verify that the media and pipeline operating parameters comply with the manufacturer's declarations.
Any change in the operating conditions must be consulted with the fitting's manufacturer beforehand.
Before attempting to assemble the fitting, remove the main bore plugs, check the inner surfaces of the
fitting and thoroughly flush with water, if necessary.
Note! 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:
1. Gate valve; 2. Threaded end of a pipeline
Recommend
Permitted
Not permitted
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4.3 OPERATION
The gate valve shall be operated in accordance with 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 be covered by the suretyship
granted by the manufacturer.
4.4 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
soft-seal gate valves.
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.
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