DeZurik APCO CSV-1600A Bedienungsanleitung
DeZURIK
Instruction and Operating Manual Page 2 © 2023 DeZURIK, Inc.
Instructions
These instructions are for use by personnel who are responsible for the installation, operation and
maintenance of DeZURIK valves, actuators or accessories.
Safety Messages
All safety messages in the instructions are identified by a general warning sign and the signal word CAUTION,
WARNING or DANGER. These messages indicate procedures to avoid injury or death.
Safety label(s) on the product indicate hazards that can cause injury or death. If a safety label becomes difficult
to see or read, or if a label has been removed, please contact DeZURIK for replacement label(s).
Personnel involved in the installation or maintenance of valves should be constantly alert to potential
emission of pipeline material and take appropriate safety precautions. Always wear suitable protection
when dealing with hazardous pipeline materials. Handle valves which have been removed from service
with suitable protection for any potential pipeline material in the valve.
Inspection
Your DeZURIK product has been packaged to provide protection during shipment; however, items can be
damaged in transport. Carefully inspect the unit for damage upon arrival and file a claim with the carrier if
damage is apparent.
Parts
Replaceable wear parts are listed on the assembly drawing. These parts can be stocked to minimize
downtime. Order parts from your local DeZURIK sales representative or directly from DeZURIK. When ordering
parts please provide the following information:
If the valve has a data plate: please include the 7-digit part number with either 4-digit revision number
(example: 9999999R000) or 8-digit serial number (example: S1900001) whichever is applicable. The
data plate will be attached to the valve assembly. Also, include the part name, the assembly drawing
number, the balloon number and the quantity stated on the assembly drawing.
If there isn't any data plate visible on the valve: please include valve model number, part name, and
item number from the assembly drawing. You may contact your local DeZURIK Representative to help
you identify your valve.
DeZURIK Service
DeZURIK service personnel are available to maintain and repair all DeZURIK products. DeZURIK also offers
customized training programs and consultation services. For more information, contact your local DeZURIK
sales representative or visit our website at DeZURIK.com.
DeZURIK
APCO CSV-1600A Surge Check Valves
March 2023 Page 3 D12050
Table of Contents
Description ........................................................................................................................................................4
Handling and Storage........................................................................................................................................4
Installation.........................................................................................................................................................4
Fusion Bonded Epoxy Coated Valves................................................................................................................4
Maintenance......................................................................................................................................................5
Disassembly Procedure.................................................................................................................................5
Assembly Procedure......................................................................................................................................5
Flow Adjustment ............................................................................................................................................6
Operation ..........................................................................................................................................................7
Drawings ...........................................................................................................................................................8
Figure 1: CSV-1600A Surge Check Valve......................................................................................................8
Figure 2: CSV-1600A Surge Check Valve (Exploded View)...........................................................................9
Troubleshooting...............................................................................................................................................10
DeZURIK
APCO CSV-1600A Surge Check Valves
March 2023 Page 4 D12050
Description
APCO CSV-1600A Surge Check Valve is designed for installation to the inlet of the existing Air/Vacuum Valve
on the line. It consists of a body, seat and plug. After air passes through and water rushes into the surge
check, the plug starts to close, reducing the rate of flow of water into the air valve by means of throttling orifices
in the disc to prevent water hammer in the air valves. If necessary, flow can be controlled in the field by
installing NPT plugs into the orifices of the valve plug.
Handling and Storage
Lifting the valve improperly may damage it. Do not fasten lifting devices through the seat opening in the body.
Lift the valve with slings, chains or cables fastened around the valve body, or fastened to bolts or rods through
bolt holes in the flanges.
If installation will be delayed, refer to Form 1454 –Recommended Long & Short-Term Storage
Procedures.
Installation
The Surge Check Valve should always be installed in a vertical position. An isolation valve between this unit
and the transmission (pipeline) system is recommended.
•Before installation, remove foreign material such as weld spatter, oil, grease, and dirt from the pipeline.
•Prepare pipe ends and install valves in accordance with the pipe manufacture’s instructions for the joint
used.
Do not deflect the pipe-valve joint. Minimize bending stresses in the valve end
connection with pipe loading.
•Tighten the flange bolts or studs in a crisscross pattern and minimum of four stages.
Fusion Bonded Epoxy Coated Valves
Valves with fusion bonded epoxy coated exterior paint require flat washers to be
installed under the flange nuts when installing the valve to the pipeline flange to
prevent the coating from cracking or chipping.
DeZURIK
APCO CSV-1600A Surge Check Valves
March 2023 Page 5 D12050
Maintenance
The APCO Surge Check Valve is automatic in operation and requires very little maintenance. It should always
be installed in a vertical position.
A semi-annual visual inspection for leakage is recommended. A malfunction of the Surge Check Valve can be
identified by a substantial amount of spillage through the exhaust port during pump start-up. Should a
malfunction occur, the following steps should be taken to repair the valve:
Disassembly Procedure
See Figures 1 & 2 for part identification.
Servicing the Surge Check Valve while the pipeline is under pressure can cause
personal injury or equipment damage. Relieve pipeline pressure or shut off isolation
valve before servicing the Surge Check Valve.
1. Relieve pipeline pressure or shut off isolation valve before servicing the Surge Check Valve.
2. Remove the Air/Vacuum Valve from the Surge Check Valve.
3. Loosen seat retaining screws (S06).
4. Remove seat (S02). In some cases, it may be necessary to use penetrating oil or rust solvent to loosen
the rust that may have formed between the body (S01) and seat (S02). Also, it may be helpful to rotate
the seat in the body to break loose the seat retaining ball (S07). Check if the bore through the center of
the seat (S02) is worn.
5. Lift and remove plug (S03). Inspect plug assembly (S03) for any bent or worn features.
6. Remove bushing retaining ring (S11) and bushing (S05).
7. Clean all surfaces before re-assembly. Replace all defective parts.
Assembly Procedure
1. Install the parts inside the body (S01) in the following order:
a. Bushing (S05) and bushing retaining ring (S11) into the center bore of the body (S01).
b. Plug (S03) with the concave side facing upward.
c. Seat (S02) and seat retaining ball (S07). Tighten seat retaining screw (S06) when flush with flange
face.
Note: When assembled, make sure that both ends of plug stem are completely engaged in their
respective guides in both open and closed positions. Plug should freely move when
activated.
2. Attach the Air/Vacuum Valve to the Surge Check Valve.
3. If valve was removed from pipeline, place valve in pipeline, and open isolation valve on inlet to Air
Valve. Valve is now back in service.
DeZURIK
APCO CSV-1600A Surge Check Valves
March 2023 Page 6 D12050
Flow Adjustment
Flow allowed through the closed valve can be adjusted by installing NPT plugs into orifices on the plug (S03).
ASME Class 125/150 valves sized 3-12” (80-300mm):
•Orifices will require tapping prior to installing NPT plugs.
•See Table 1: Orifice NPT Plug Sizes for appropriate tap size. Orifices are proper size to receive NPT
tap.
•Tap orifice to appropriate size.
•Install NPT plugs in orifices until desirable flow conditions are met.
ASME Class 125/150 valves sized 14-24” (350-600mm) and ASME Class 250/300 valves sized 3-24” (80-
600mm):
•Supplied from the factory with threaded orifices.
•See Table 1: Orifice NPT Plug Sizes for appropriate NPT plug size.
•Install NPT plugs in orifices until desirable flow conditions are met.
Valve Size
(in/mm)
Orifice NPT Plug Size
ASME Class 125/150
ASME Class 250/300
3
80
* 1/8” NPT
1/8” NPT
4
100
* 1/8” NPT
1/8” NPT
6
150
* 1/8” NPT
1/8” NPT
8
200
* 1/8” NPT
1/8” NPT
10
250
* 1/8” NPT
1/8” NPT
12
300
* 1/4” NPT
1/4” NPT
14
350
1/4” NPT
1/4” NPT
16
400
1/4” NPT
1/4” NPT
18
450
3/8” NPT
3/8” NPT
*ASME Class 125/150 sizes 3-12” (80-300mm) valves will need to
be tapped prior to NPT plug installation.
Table 1: Orifice NPT Plug Sizes
DeZURIK
APCO CSV-1600A Surge Check Valves
March 2023 Page 7 D12050
Operation
The Surge Check Valve is a normally open valve that air passes through unrestricted. When water rushes into
the Surge Check unit, the disc begins to close against the seat and reduces the rate of flow of water into the air
valve by means of throttling holes in the disc. This ensures normal gentle closing of the Air/Vacuum Valve
regardless of the initial velocity flows involved and minimizes pressure surges when the valve closes.
As soon as the Air/Vacuum Valve is closed, the pressure on both sides of the Surge Check Valve disc
equalizes and the disc automatically returns to its open position. This means the Air/Vacuum Valve does not
need an incipient vacuum to open, but can open at any time the water level drops and line pressure
approaches atmospheric. This will allow immediate full re-entry flow of air into the pipeline before a vacuum
can form.
DeZURIK
APCO CSV-1600A Surge Check Valves
March 2023 Page 8 D12050
Drawings
Item No.
Description
S01
BODY
S02
SEAT
S03
PLUG
S05
BUSHING
S06
SEAT RETAINING SCREW
S07
SEAT RETAINING BALL
S11
BUSHING RETAINING RING (NOTE 1)
Note 1: When corrosion resistant body materials are
used, a threaded retainer is used. Standard retainer is
a retaining ring as shown in the drawing.
Figure 1: CSV-1600A Surge Check Valve
DeZURIK
APCO CSV-1600A Surge Check Valves
March 2023 Page 9 D12050
Drawings (Continued)
Figure 2: CSV-1600A Surge Check Valve (Exploded View)
DeZURIK
APCO CSV-1600A Surge Check Valves
March 2023 Page 10 D12050
Troubleshooting
Condition
Possible Cause
Corrective Action
Valve will not close.
Plug stem may be worn and may
have come out of the guide.
Replace Plug.
Valve will not open.
Improper installation.
Flow arrow on valve body should
be pointing in direction of flow.
Valve leaks at flange joint.
Loose flange bolting.
Tighten flange bolting.
Blown flange gasket.
Replace flange gasket.
Misalignment or damage to field
piping and supports.
Adjust misalignment or repair
piping or supports.
Damaged flange face/s or
improper flange connections.
Repair flange, replace valve
body or adjust flange
connections.
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