AVK 41 Series Gebrauchsanweisung

AVK SERIES 41 CHECK VALVE

INSTALLATION, OPERATION & MAINTENANCE MANUAL

Instruction for use

Thank you for selecting an AVK product. With correct use, the product is guaranteed to deliver a long and

reliable service. This manual has been prepared to assist you with the installation, operation and maintenance

of the valve to the maximum efficiency. For ease of reference, it has been divided into sections covering all

aspects of use, and it is in the users best interests to read it and ensure that it is fully understood.

Health and Safety

It is always recommended that wherever work is being carried out on a valve that the valve is fully

depressurised prior to carrying it out, and for the convenience draining of the line may be beneficial.

It is essential that the user of the valve is aware of the weight of the components and/or assembles that must

be handled and manipulated during installation and maintenance. It is the users responsibility to ensure that

safe working practices are followed at all times.

Whenever AVK products are installed, operated, or maintained, it is essential that the staff that undertake

these operations be adequately trained. The hazards of pressurised liquids and gases can be severe, and it

is the responsibility of the users to ensure that trained, competent staff undertake these duties. This manual

has been designed to assist, but it can never fully replace quality training in the workplace. AVK technical staff

will always be available to answer any questions relating to specific problems that may not be covered by this

manual.

AVK products are designed and manufactured to be fit for purpose, and to a high and reliable standard. This

provides a safe product with minimum risk to health when used correctly for the purpose for which it was

designed. However, this assumes that the equipment is used and maintained in accordance with the manual,

and the user is advised to study this manual, and to make it available to all staff that may need to refer to it.

AVK cannot be held responsible for any incidents arising from incorrect installation, operation or maintenance.

The responsibility for this must rest wholly with the user.

AVK Valves Pty Ltd, 559A Grand Junction Road, Wingfield, SA 5013, Australia - T: +61 8 8368 0900 - E: [email protected] - W: www.avkcivil.com.au Version number 3

AVK SERIES 41 CHECK VALVE

INSTALLATION, OPERATION & MAINTENANCE MANUAL

Storage

• The valve should not come into contact with any contaminative substances prior to installation

• Valve end protectors (if supplied) should not be removed unless necessary for inspection or installation.

• Protection against weather should be provided. Ideally, valves should be kept indoors with the actual valve temperature

always higher than the dew point, particularly for valves ﬁtted with actuators.

• If outdoor storage is unavoidable the valves should then be supported off the ground and protected by a weatherproof cover,

from dust-laden damp or saline conditions and at an ambient temperature.

• If long term storage is envisaged, then it may be considered prudent to have a AVK engineer inspect the valve prior to

installation.

Handling

A basic consideration in handling protected valves should be to avoid damaging the coating protection and valves should never

be thrown or dropped. Valves whose size requires handling by crane or lift truck should be slung or rigged carefully to avoid

damage to exposed valve parts.

Handwheels, bypass, actuators and gearboxes in particular, should not be used as lifting or rigging points for valves.

AVK Valves Pty Ltd, 559A Grand Junction Road, Wingfield, SA 5013, Australia - T: +61 8 8368 0900 - E: [email protected] - W: www.avkcivil.com.au Version number 3

AVK SERIES 41 CHECK VALVE

INSTALLATION, OPERATION & MAINTENANCE MANUAL

1. Introduction

The AVK series 41 Swing Check Valves are designed for horizontal or vertical ﬂow (not suitable for down-ﬂow applications). The

design permits full bore ﬂow and enables correct alignment of the resilient seated disc to the body seating surface. The valve

comes equipped with a bolted bonnet which can be removed while the valve is in the line.

Materials:

Body and bonnet

Ductile Iron to AS 1831

Coating

Electrostatically applied epoxy resin to AS 4158 - Internally

and externally

Shaft

Stainless Steel

Bonnet gasket

EPDM rubber

Bushing

Copper alloy AS/NZS 1567

Hexagon bolt, washer and pin

Stainless Steel

Resilient seated disc

EPDM rubber with a steel insert

Hinge

DN 80 - 200: Stainless steel

DN 250 - 300: Ductile Iron to AS 1831

Accessory kit:

Weight, hinge lever and weight

Ductile Iron to AS 1831

Cam

Stainless Steel

AVK Valves Pty Ltd, 559A Grand Junction Road, Wingfield, SA 5013, Australia - T: +61 8 8368 0900 - E: [email protected] - W: www.avkcivil.com.au Version number 3

AVK SERIES 41 CHECK VALVE

INSTALLATION, OPERATION & MAINTENANCE MANUAL

Component list

1. Body

2. Bushing closed

3. Bonnet

4. Hexagon bolt

5. Washer

6. Bushing open

7. Lever

8. Nut

9. Washer

10. Weight

11. Grub screw

12. O-ring

13. O-ring

14. O-ring

15. Shaft

16. Bonnet gasket

17. Tab washer

18. Nut

19. Washer

20. Bushing

21. Hinge

22. Rubber disc

23. Hexagon bolt

24. Shaft protector

25. Connector

26. Key

27. Retaining washer

28. Spacer

Dt Dh D

1 2 3 4567

18 19 20 21 22

12 13 14 15

25 26 27 28

DN80, 100, 150 and 200 DN250-300

Lever and weight as optional extras 23

AVK Valves Pty Ltd, 559A Grand Junction Road, Wingfield, SA 5013, Australia - T: +61 8 8368 0900 - E: [email protected] - W: www.avkcivil.com.au Version number 3

AVK SERIES 41 CHECK VALVE

INSTALLATION, OPERATION & MAINTENANCE MANUAL

2. Installation

a) When installing the check valves, ensure that the seats and the ﬂange faces are clean.

b) When valves are provided with lifting lugs, plates or eye nuts, these must be used to lift the valve.

c) To ensure adequate sealing it is important to select the correct type of gasket for the medium concerned, gaskets with the

correct ﬂange size must be used.

d) Place valve between pipe ﬂanges, and insert the bolts.

e) Tighten bolts loosely.

f) Tighten bolts in a diagonal sequence to ensure ﬂanges are pulled parallel.

g) Finally tighten bolts to correct torque levels as recommended in WSA 109.

2.1. Bolts

2.1.1 Bolt size

The following table shows bolt size you should use for which valve dimensions.

AS 2129 AS 2129

Table B5 Table E Table F

DN Bolts Quantity Bolts Quantity Bolts Quantity

50 M16 4 M16 4 M16 4

80 M16 4 M16 4 M16 8

100 M16 4 M16 8 M16 8

150 M16 8 M20 8 M20 12

200 M16 8 M20 8 M20 12

225 M16 8 - - - -

250 M16 8 M20 12 M24 12

300 M20 12 M24 12 M24 16

375 M24 12 M24 12 M27 16

400 M24 12 M24 12 M27 20

AVK Valves Pty Ltd, 559A Grand Junction Road, Wingfield, SA 5013, Australia - T: +61 8 8368 0900 - E: [email protected] - W: www.avkcivil.com.au Version number 3

AVK SERIES 41 CHECK VALVE

INSTALLATION, OPERATION & MAINTENANCE MANUAL

page 4

Top View

Direction of Flow

Fig. 2

Horizontal Mounting

Front View

page 5

Fig. 3

Vertical Mounting

Direction

Flow

Rear View Front View

Horizontal Mounting

Vertical Mounting

AVK Valves Pty Ltd, 559A Grand Junction Road, Wingfield, SA 5013, Australia - T: +61 8 8368 0900 - E: [email protected] - W: www.avkcivil.com.au Version number 3

AVK SERIES 41 CHECK VALVE

INSTALLATION, OPERATION & MAINTENANCE MANUAL

Open Position

Closed Position

Open Position

page 6

Fig. 4

Optimal Leverage

Congurations

Horizontal Mounting

Vertical Mounting

Direction

Flow

Direction of Flow

Lever & weight positions

AVK Valves Pty Ltd, 559A Grand Junction Road, Wingfield, SA 5013, Australia - T: +61 8 8368 0900 - E: [email protected] - W: www.avkcivil.com.au Version number 3

AVK SERIES 41 CHECK VALVE

INSTALLATION, OPERATION & MAINTENANCE MANUAL

3. Operation

Series 41 Swing Check Vlaves are suitable for use with wholesome (potable) water and low solids sewage up to 70oC. Minimum

liquid temperature must be above freezing.

Insulation is recommended for external temperatures from 0oC to -10oC. They can have a Lever & Weight option, Right Hand

as standard.

Design Constraints

Please consider the following points when selecting your valve:

Consideration should be given at the design stage where valves will be located to give access for operation, adjustment,

maintenance and repair.

If a valve is installed less than 5 pipe diameters upstream or downstream of any pump elbow or tee etc., it will experience very

high-localised velocities that are far in excess of the average velocity. This high velocity will result in excessive turbulence within

the valve and variations in performance may be experienced, therefore installation in this area should be avoided.

Valves must be provided with adequate support. Adjoining pipework must be supported to avoid the imposition of pipeline

strains on the body which may impair its performance.

Full ﬂow is achieved with the disc positioned in the bonnet cavity, this occurs when velocity is greater than 1.5m/s. Velocities

above 4.5m/s can result in disc ﬂutter reducing pump efﬁciencies and reducing the life of the valve.

For disc to seal a static pressure differential of a minimum of 70kpa is required.

AVK Valves Pty Ltd, 559A Grand Junction Road, Wingfield, SA 5013, Australia - T: +61 8 8368 0900 - E: [email protected] - W: www.avkcivil.com.au Version number 3

AVK SERIES 41 CHECK VALVE

INSTALLATION, OPERATION & MAINTENANCE MANUAL

4. Maintenance

The valve is designed for use with minimum maintenance and requires no lubrication.

In the event of a spares replacement becoming necessary, the recommended procedure is as follows:

SAFETY PRECAUTIONS

a) Procedures must NOT be carried out whilst the valve is installed in a live main under pressure.

b) Ensure main will NOT be recharged before all work on the valve is completed.

4.1 Replacement of Brass Sealing Bushes with 'O' Ring Seals.

This can only be carried out when there is no pressure in the pipeline.

a) If ﬁtted remove nut (8), washer (9) and lever (7) with weight (10).

NOTE: position of lever relative to body (1) for re-assembly.

b) Unscrew either bushing (2) or (6) and replace with new bushing complete with 'O' ring seals.

c) Repeat step b) with opposite side bushing.

d) Where necessary, reﬁt lever (7), weight (10), washer (9) and nut (8).

Component list

1. Body

2. Bushing closed

3. Bonnet

4. Hexagon bolt

5. Washer

6. Bushing open

7. Lever

8. Nut

9. Washer

10. Weight

11. Grub screw

12. O-ring

13. O-ring

14. O-ring

15. Shaft

16. Bonnet gasket

17. Tab washer

18. Nut

19. Washer

20. Bushing

21. Hinge

22. Rubber disc

23. Hexagon bolt

24. Shaft protector

25. Connector

26. Key

27. Retaining washer

28. Spacer

Dt Dh D

1 2 3 4567

18 19 20 21 22

12 13 14 15

25 26 27 28

DN80, 100, 150 and 200 DN250-300

Lever and weight as optional extras 23

AVK Valves Pty Ltd, 559A Grand Junction Road, Wingfield, SA 5013, Australia - T: +61 8 8368 0900 - E: [email protected] - W: www.avkcivil.com.au Version number 3

AVK SERIES 41 CHECK VALVE

INSTALLATION, OPERATION & MAINTENANCE MANUAL

4.2 Replacement of Complete Bonnet Assembly (complete with Shaft, Hinge, Disc and Bushings).

This can only be carried out when there is no pressure in the pipeline.

a) Remove bonnet (3) by removing hexagon screws (4) and washers (5) and lift completed assembly from body (1).

(NOTE: Screws are different lengths.)

NOTE: If bushings only are to be replaced, follow steps in 4.1.

Check free movement of hinge prior to re-assembling of body.

a) Ensure that seat area in body is clean.

b) Fit hexagon screws (4) and washers (note different lengths) (5) through bonnet (1) and ﬁt bonnet gasket (16) over screws

(4).

Fit bonnet (3) into body (1) with disc (23) facing correct way.

c) Tighten bonnet screws (4) in a diagonal sequence using torque wrench set at 25Nm to 30Nm. Reset the torque Wrench at

40Nm to 50Nm and re-tighten the screws following a circumferential sequence.

d) Slowly re-charge the main and check integrity of seals.

Component list

1. Body

2. Bushing closed

3. Bonnet

4. Hexagon bolt

5. Washer

6. Bushing open

7. Lever

8. Nut

9. Washer

10. Weight

11. Grub screw

12. O-ring

13. O-ring

14. O-ring

15. Shaft

16. Bonnet gasket

17. Tab washer

18. Nut

19. Washer

20. Bushing

21. Hinge

22. Rubber disc

23. Hexagon bolt

24. Shaft protector

25. Connector

26. Key

27. Retaining washer

28. Spacer

Dt Dh D

1 2 3 4567

18 19 20 21 22

12 13 14 15

25 26 27 28

DN80, 100, 150 and 200 DN250-300

Lever and weight as optional extras 23

AVK Valves Pty Ltd, 559A Grand Junction Road, Wingfield, SA 5013, Australia - T: +61 8 8368 0900 - E: [email protected] - W: www.avkcivil.com.au Version number 3