Operation
and Maintenance Manual
Approved for use by
CHECK
BALL
VALVES
P/N
6516
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 warranty.
Due to the continuous development of the company, we reserve the right to
modifications and design changes in the product presented herein.
OPERATION AND MAINTENANCE MANUAL 09-2015
CONTENTS
1 TECHNICAL DESCRIPTION ............................................................................................................................ 3
1.1 PRODUCT DESIGNATION AND IDENTIFICATION .............................................................................. 3
1.2 USE ............................................................................................................................................................... 3
1.3 TECHNICAL CHARACTERISTICS ........................................................................................................... 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 ........................................................................................................ 6
2.7 MARKING .................................................................................................................................................... 6
3 PROTECTION, STORAGE & TRANSPORT .................................................................................................... 7
3.1 PROTECTIVE COATINGS ......................................................................................................................... 7
3.2 PACKAGING ............................................................................................................................................... 7
3.3 STORAGE .................................................................................................................................................... 7
3.4 TRANSPORT ............................................................................................................................................... 7
4 ASSEMBLY AND INSTALLATION ................................................................................................................. 8
4.1 ASSEMBLY GUIDELINES ......................................................................................................................... 8
4.2 ASSEMBLY INSTRUCTIONS .................................................................................................................... 8
4.3 OPERATION ................................................................................................................................................ 8
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 6516 cast iron flanged check ball valve
- full bore design
- ball (closure) embedded in 100% pure elastomer
- valve cover o-ring seal
- cover flush-bolted to body
1.2 USE
The Type 6516 flanged check ball valves are intended for industrial installations, e.g. sewage
discharge, or water supply systems, e.g. for potable water. The valves are intended for overground and
underground installations as installed in vertical or horizontal pipelines.
The Type 6516 cast iron flanged check ball valves are intended for pumping systems.
1.3 TECHNICAL CHARACTERISTICS
The Type 6516 cast iron flanged check ball valve are designed to transport potable water, process
water (sewage) and other liquids as approved by the manufacturer.
- Operating temperature: -10°C to +70°C
- Available diameters (dimensions): - DN50 to DN500 [mm] for Type 6516 valves
- Maximum medium flow rate: - liquid: max. 4 [m/s]
- nominal pressure ratings (PN): - 1.0 MPa
- 1.6 MPa
Maximum opening break-off pressure at zero back pressure:
DN [mm]
Pmax [MPa]
50 65 80 100 125 150 200 250 300 350 400 500
0.01 0.02 0.03 0.04 0.05
The Type 6516 valve connection flange design is acc. to PN-EN 1092-2: 1999 with the sizes compliant
with the nominal pressure values.
Installation length of (Type 6516) flange valves is acc. to PN-EN 558+A1: 2012, series 48.
2 DESIGN
2.1 DESCRIPTION OF THE VALVE DESIGN
F.A. „JAFAR” S.A. manufactures the Type 6516 (flanged) check ball valves for pumping systems. The
valve features a cast iron body that houses a loose ball inside (the closure). The body chamber is closed from the
top by a cast-iron cover that is sealed with an o-ring and bolted to the body with hex cap bolts which are flush
with the valve cover seats. The ball in the valve before installation is located in the lowest valve body part, i.e.
directly at the sealing seat and rests freely on the guides (or, if the valve installation orientation is horizontal, the
ball sits in the valve seat). In the operating conditions, the ball is held at the top position (under the valve cover)
by the dynamic force of the liquid stream, or in the closed position, where it seals off the valve seat under the
back pressure. All inner and outer cast-iron surfaces of the valve are epoxy powder coated.
The check ball valves for pumping systems have the ball density higher than water.
The valve can be custom ordered with a cleaning valve (B) or a standard cleanout hole (A).
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2.2 MATERIALS
The table below lists the structural materials of the check ball valves.
Item Part designation Material Reference standard
1 Body
2 Cover
3 Rubber-embedded ball
Spheroidal cast iron
EN-GJS-400-15
Spheroidal cast iron
EN-GJS-400-15
Cast iron or aluminium alloy
in rubber coating: NBR (or EPDM)
PN-EN 1563: 2012
PN-EN 1563: 2012
PN-EN 1563: 2012
PN-EN 1706: 2010
PN-ISO 1629: 2005
4 Valve cover gasket Rubber: NBR (or EPDM) PN-ISO 1629: 2005
Bolt, cap,
5
hex
6 Bolt plug Paraffin
Acc. to reference standards PN-EN ISO 4762: 2006
acc. to manufacturer's Technical
Guidelines
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2.3 DIMENSIONS
L
PN16 PN10
Series 48
H d D K I C f n
[mm]
DN PN
[mm] [bar] - [kg]
50 200 113 102 165 125 19 20 3 4 8
65 240 126 122 185 145 19 20 3 4 13
80 260 162 138 200 160 19 22 3 8 17
100 300 194 158 220 180 19 24 3 8 24
125 350 214 188 250 210 19 22 3 8 34
150 400 260 212 285 240 23 26 3 8 52
200 500 320 268 340 295 23 22 3 12 83
250 600 365 320 405 350 23 30 3 12 136
300 700 427 378 460 400 23 30 4 12 229
350 800 427 429 520 460 23 32 4 16 260
400 900 537 480 580 515 28 32 4 16 395
500 1100 650 582 670 620 28 34 4 20 560
Weight
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2.4 REFERENCE STANDARDS
PN-EN 1074-1: 2002 Valves for water supply. Fitness for purpose requirements and appropriate
verification tests. General requirements
PN-EN 1074-3: 2002 Valves for water supply. Fitness for purpose requirements and appropriate
verification tests. Check valves.
PN-89/H-02650 Valves and pipelines. Pressure and temperature ratings.
PN-EN 1092-2: 1999 Flanges and their joints. Circular flanges for pipes,
valves, fittings and accessories, PN designated. Cast iron flanges.
PN-EN 19: 2005 Industrial valves. Marking of metallic valves
PN-EN 12266-1: 2012 Industrial valves. Testing of metallic valves. Pressure tests, test procedures
and acceptance criteria. Mandatory requirements.
PN-EN 558: 2012 Industrial valves. Face-to-face and centre-to-face dimensions of metal valves
for use in flanged pipe systems. PN-designated valves.
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-EN 1563: 2012 Founding. Spheroidal graphite cast irons.
PN-EN 1370: 2012 Founding. Surface roughness inspection by
visual tactile comparators.
PN-ISO 965-1: 2001 ISO general purpose metric screw threads. Tolerances. Principles and basic
data.
PN-EN ISO 4762: 2006 Hexagon socket head cap screws.
DIN 6912: 2006 Hexagon socket low head cap screws.
PN-EN 10204: 2006 Metallic products. Types of inspection documents.
PN-ISO 1629: 2005 Rubbers and latices. Nomenclature.
PN-EN ISO 1872-1: 2000 Plastics. Polyethylene (PE) moulding and extrusion materials. Designation
system and basis for specifications.
PN-EN ISO 1873-1: 2000 Plastics. Polypropylene (PP) moulding and extrusion materials. Designation
system and basis for specifications.
PN-EN ISO 1874-1: 2010 Plastics. Polyamide (PA) moulding and extrusion materials. Designation
system and basis for specification.
PN-EN ISO 12944-5: 2009 Paints and varnishes. Corrosion protection of steel structures by protective
paint systems. Protective paint 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 sewage;
and:
- 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
- maximum operating temperature, acc. to PN-89/H-02650.
2.6 PRODUCTION AND ACCEPTANCE
The check ball valves are accepted and produced in accordance with PN-EN 1074-3: 2002 (Valves for water
supply. Fitness for purpose requirements and appropriate verification tests. Check valves) and PN-EN 12266-1:
2007 (Industrial valves. Testing of valves). All valves are leak tested (100%). The tests include external body
tightness and closing tightness at high and low pressure values.
2.7 MARKING
The valve marking is regulated by the following standards: PN-EN-19: 2005, PN-EN-1074-1: 2002.
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The 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 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 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
PN-EN ISO 12944-5: 2009.
The cover-to-body fastening bolts are grade OH18N9 (stainless steel) or Fe/Zn5 (galvanized steel).
3.2 PACKAGING
The flanged check ball valves are packed on EURO pallets (1200x800) and protected with heat-shrunk
film.
3.3 STORAGE
Store the check ball valves in sheltered rooms.
3.4 TRANSPORT
Transport the check ball valves on sheltered vehicles. The following diagram shows an example of
vertical handling on belt slings.
The ball valves from DN100 to DN5000 shall be installed and handled with slings.
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4 ASSEMBLY AND INSTALLATION
4.1 ASSEMBLY GUIDELINES
The Type 6516 check ball valves can be installed in underground or overground pipelines both in
horizontal or vertical orientation as shown in the following figure. The flanged valves 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 valve to bending or tensile stress from loading with the unsupported pipeline sections. The valve
assembled and delivered by the manufacturer is ready for installation. Disassembly of the valve components
without proper care may result in loss of integrity.
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.
The assembly method is shown in the following figure:
1. Valve; 2. Nut; 3. Gasket; 4. Pipeline flange; 5. Washer; 6. Fastening bolt
CAUTION!
Install the valve downstream of a straight pipeline the length of which is at least 5 times the pipeline
nominal diameter.
4.3 OPERATION
The flanged check ball valves shall be operated according to the requirements for check valves, i.e. in the
orientation shown in the permitted orientation diagram. The check ball valve has a self-cleaning action. However,
it is recommended to periodically purge the valve with fresh water (once a year) to assure full performance. Hard
solids with the size above 5 mm should be filtered out of the transmitted medium to prevent seizure of the ball
inside the body and damage to the rubber ball coat. If the ball is stuck, start the installation pump for a few
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seconds. If the problem persists, stop all installation pumps, isolate the medium flow on the valve's pressure side,
open the valve cover and free the ball.
4.4 OCCUPATIONAL HEALTH AND SAFETY
The 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
The product assembled, installed and operated in compliance with this Manual is covered by a
commercial warranty from the manufacturer. The warranty terms, conditions and period are specified in the
relevant Warranty Sheet.
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