Spirax Sarco DCV1 Bedienungsanleitung

IM-S19-04-EN-ISS1 CMGT 1

1. Safety information

2. General product information

3. Installation

4. Commissioning

5. Operation

6. Maintenance

7. Spare parts

Printed in France

1340050/7

DCV1, DCV3 and DCV3LT

Disc Check Valves

Installation and Maintenance Instructions

IM-S19-04-EN-ISS1

CMGT

PREVIOUS REFERENCE NO. IM-P134-07

IM-S19-04-EN-ISS1 CMGT

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Safe operation of these products can only be guaranteed if they are properly installed,

commissioned, used and maintained by qualified personnel (see Section 1.11) in compliance with

the operating instructions. General installation and safety instructions for pipeline and plant

construction, as well as the proper use of tools and safety equipment must also be complied with.

1.1 Intended use

Referring to the Installation and Maintenance Instructions, name-plate and Technical Information

Sheet, check that the products are suitable for the intended use/application. The products

listed below comply with the requirements of the Pressure Equipment Directive (PED) and carry

the mark when so required. The products fall within the following Pressure Equipment

Directive category:

Product Group 1

Gases

Group 2

Gases

Group 1

Liquids

Group 2

Liquids

DCV1,

DCV3

and

DCV3LT

DN15 - DN25 SEP SEP SEP SEP

DN32 2SEP SEP SEP

DN40 - DN50 2 1 SEP SEP

DN65 - DN80 2 1 2 SEP

DN100 2 1 2 SEP

i) The product has been specifically designed for use on steam, compressed air and water/

condensate which are in Group 2 of the above mentioned Pressure Equipment Directive.

ii) Check material suitability, pressure and temperature and their maximum and minimum values.

If the maximum operating limits of the product are lower than those of the system in which it

is being fitted, or if malfunction of the product could result in a dangerous overpressure or

overtemperature occurrence, ensure a safety device is included in the system to prevent such

over-limit situations.

iii) Determine the correct installation situation and direction of fluid flow.

iv) Spirax Sarco products are not intended to withstand external stresses that may be induced

by any system to which they are fitted. It is the responsibility of the installer to consider these

stresses and take adequate precautions to minimise them.

v) Remove protection covers from all connections and protective film from all name-plates, where

appropriate, before installation on stream or other high temperature applications.

1.2 Access

Ensure safe access and if necessary a safe working platform (suitably guarded) before attempting

to work on the product. Arrange suitable lifting gear if required.

1.3 Lighting

Ensure adequate lighting, particularly where detailed or intricate work is required.

1. Safety information

IM-S19-04-EN-ISS1 CMGT 3

1.4 Hazardous liquids or gases in the pipeline

Consider what is in the pipeline or what may have been in the pipeline at some previous time.

Consider: flammable materials, substances hazardous to health, extremes of temperature.

1.5 Hazardous environment around the product

Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of

temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.

1.6 The system

Consider the effect on the complete system of the work proposed. Will any proposed action (e.g.

closing isolation valves, electrical isolation) put any other part of the system or any personnel

at risk?

Dangers might include isolation of vents or protective devices or the rendering ineffective of

controls or alarms. Ensure isolation valves are turned on and off in a gradual way to avoid system

shocks.

1.7 Pressure systems

Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double

isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume

that the system has depressurised even when the pressure gauge indicates zero.

1.8 Temperature

Allow time for temperature to normalise after isolation to avoid the danger of burns and consider

whether protective clothing (including safety glasses) is required.

Viton seat:

If the Viton seat has been subjected to a temperature approaching 315 °C (599 °F) or higher it may

have decomposed and formed hydrofluoric acid. Avoid skin contact and inhalation of any fumes

as the acid will cause deep skin burns and damage the

respiratory system.

1.9 Tools and consumables

Before starting work ensure that you have suitable tools and/or consumables available. Use only

genuine Spirax Sarco replacement parts.

1.10 Protective clothing

Consider whether you and/or others in the vicinity require any protective clothing to protect against

the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling objects, and

dangers to eyes and face.

1.11 Permits to work

All work must be carried out or be supervised by a suitably competent person. Installation and

operating personnel should be trained in the correct use of the product according to the Installation

and Maintenance Instructions.

Where a formal 'permit to work' system is in force it must be complied with. Where there is no such

system, it is recommended that a responsible person should know what work is going on and, where

necessary, arrange to have an assistant whose primary responsibility is safety.

Post 'warning notices' if necessary.

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1.12 Handling

Manual handling of large and/or heavy products may present a risk of injury. Lifting, pushing,

pulling, carrying or supporting a load by bodily force can cause injury particularly to the back.

You are advised to assess the risks taking into account the task, the individual, the load and the

working environment and use the appropriate handling method depending on the circumstances

of the work being done.

1.13 Residual hazards

In normal use the external surface of the product may be very hot. If used at the maximum

permitted operating conditions the surface temperature of some products may reach

temperatures of 300 °C (572 °F).

Many products are not self-draining. Take due care when dismantling or removing the product from

an installation (refer to 'Maintenance instructions').

1.14 Freezing

Provision must be made to protect products which are not self-draining against frost damage in

environments where they may be exposed to temperatures below freezing point.

1.15 Disposal

This product is recyclable. No ecological hazard is anticipated with the disposal of this product

providing due care is taken, except:

Viton seat:

-Waste parts can be landfilled, when in compliance with National and Local regulations.

-Parts can be incinerated, but a scrubber must be used to remove Hydrogen Fluoride, which is

evolved from the product and with compliance to National and Local regulations.

-Parts are insoluble in aquatic media.

1.16 Returning products

Customers and stockists are reminded that under EC Health, Safety and Environment Law,

when returning products to Spirax Sarco they must provide information on any hazards and the

precautions to be taken due to contamination residues or mechanical damage which may present a

health, safety or environmental risk. This information must be provided in writing including Health

and Safety data sheets relating to any substances identified as hazardous or potentially hazardous.

IM-S19-04-EN-ISS1 CMGT 5

2.1 General description

The DCV1, DCV3 and DCV3LT disc check valves are of the wafer pattern designed to be sandwiched between

flanges. They are suitable for use on a wide range of fluids for applications in process lines, hot water

systems, steam and condensate systems etc. Face-to-face dimensions conform to EN 558 part 1, series 49.

As standard the valves have a metal-to-metal seat. See Section 2.5 for other options which are available

on request.

Note: For additional information see Technical Information Sheets TI-P142-01-EN-ISS1 for the DCV1 or

TI-P143-01-EN-ISS1 for the DCV3 and DCV3LT.

2.2 Sizes and pipe connections

DN15, DN20, DN25, DN32, DN40, DN50, DN65, DN80 and DN100.

Suitable for installation between BS 10 Tables 'E' and 'H'.

EN 1092 PN6, PN10, PN16, PN25 and PN40; JIS 5, JIS 10, JIS 16 and JIS 20 flanges with the following

exceptions:

DN40, DN50, DN80 and DN100 - will not fit between JIS 5 flanges.

DN65 and DN80 - will not fit between BS 10 'E' flanges.

2.3 Optional extras

Heavy duty springs (700 mbar [10 psi] opening pressure up to DN65) for boiler feed applications.

Viton soft seats for oil, gas and steam applications.

EPDM soft seats for water applications.

Fig. 1

DCV1, DCV3 and DCV3LT

2. General product information

IM-S19-04-EN-ISS1 CMGT

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2.4 Materials

Part Material

Body

DCV1 Bronze

DCV3 Austenitic stainless steel

DCV3LT Austenitic stainless steel

Disc Austenitic stainless steel

Spring retainer Austenitic stainless steel

Standard spring Austenitic stainless steel

Heavy duty spring Austenitic stainless steel

High temperature spring Nickel alloy

2.5 Seating options

The valves are stamped to identify the internals fitted:

'N' –High temperature spring –Standard metal disc

'W' –Without spring –Standard metal disc

'H' –Heavy duty spring –Standard metal disc

'V' –Standard spring –Viton soft faced disc

'E' –Standard spring –EPDM soft faced disc

'WV' –Without spring –Viton soft faced disc

'WE' –Without spring –EPDM soft faced disc

'HV' –Heavy duty spring –Viton soft faced disc

'HE' –Heavy duty spring –EPDM soft faced disc

'T' –Valves tested to EN 12266 rate D

No identification indicates a standard spring with a metal disc.

IM-S19-04-EN-ISS1 CMGT 7

2.6 Pressure/temperature limits - DCV1

260

200

150

100

-198

50 100 150200

04 81

Temperature °C

Pressure bar g

Pressure psi g

Temperature °F

Steam

saturation

curve

The product must not be used in this region.

Please note: The figures displayed are only relevant when a metal-to-metal seat is used. If Viton or EPDM

seats are used the product is restricted to the limits of the seat material chosen.

Body design conditions for saturated steam service PN16

PMA Maximum allowable pressure 16 bar g @ 120 °C (232 psi g @ 248 °F)

TMA Maximum allowable temperature 260 °C @ 7 bar g (500 °F @ 101 psi g)

Minimum allowable temperature -198 °C (-324 °F)

PMO Maximum operating pressure for saturated steam

service 13.2 bar g @ 196 °C (191 psi g @ 355 °F)

TMO Maximum operating temperature 260 °C @ 7 bar g (500 °F @ 101 psi g)

Minimum operating temperature

Note: For lower operating temperatures consult Spirax Sarco -198 °C (-324 °F)

Temperature limits

Viton seat -25 °C to +205 °C (-13 °F to 401 °F)

EPDM seat -40 °C to +120 °C (-40 °F to 248 °F)

Designed for a maximum cold hydraulic test pressure of 24 bar g (348 psi g)

Note: Special testing to allow lower temperature operation can be provided at extra cost. Consult Spirax Sarco.

IM-S19-04-EN-ISS1 CMGT

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0 100 200 300 400 500

700

600

500

400

200

100

-14

-76

400

300

200

100

-10

-60

0 10 20 30 40

Pressure psi g

Temperature °F

2.7 Pressure/temperature limits - DCV3 and DCV3LT

The product must not be used in this region.

Use either a DCV3 with high temperature spring or DCV3/DCV3LT without spring for use in this area.

A-B-F DCV3 without spring and with high temperature spring.

A-B-D DCV3LT without spring.

E-C-F DCV3 with standard spring and heavy duty spring.

E-C-D DCV3LT with standard spring and heavy duty spring.

Please note: The figures displayed are only relevant when a metal-to-metal seat is used. If Viton or EPDM

seats are used the product is restricted to the limits of the seat material chosen.

Pressure bar g

Temperature °C

Steam

saturation

curve

Only the DCV3LT can be used down to -60 °C

IM-S19-04-EN-ISS1 CMGT 9

Body design conditions PN40

PMA Maximum allowable pressure 40 bar g @ 50 °C (580 psi g @ 122 °F)

TMA Maximum allowable temperature 400 °C @ 31.2 bar g (752 °F @ 452 psi g)

Minimum allowable temperature

DCV3 -10 °C (14 °F)

DCV3LT -60 °C

PMO Maximum operating pressure (metal-to-metal seat) 40 bar g @ 50 °C (580 psi g @ 122 °F)

TMO

Maximum

operating

temperature

Standard spring 300 °C @ 33.3 bar g (572 °F @ 483 psi g)

Heavy duty spring 300 °C @ 33.3 bar g (572 °F @ 483 psi g)

High temperature

spring DCV3 only 400 °C @ 31.2 bar g (752 °F @ 452 psi g)

Without spring 400 °C @ 31.2 bar g (752 °F @ 452 psi g)

Minimum operating temperature

Note: For lower operating temperatures

consult Spirax Sarco

DCV3 -10 °C (14 °F)

DCV3LT -60 °C

Temperature limits

Viton seat -25 °C to +205 °C (-13 °F to 401 °F)

EPDM seat -40 °C to +120 °C (-40 °F to 248 °F)

Designed for a maximum cold hydraulic test pressure of 60 bar g (870 psi g)

IM-S19-04-EN-ISS1 CMGT

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Note: Before actioning any installation observe the 'Safety information' in Section 1.

Referring to the Installation and Maintenance Instructions, name-plate and Technical Information Sheet,

check that the product is suitable for the intended installation:

3.1 Check materials, pressure and temperature and their maximum values. If the maximum operating

limit of the product is lower than that of the system in which it is being fitted, ensure that a safety

device is included in the system to prevent overpressurisation.

3.2 Determine the correct installation situation and the direction of fluid flow.

3.3 Remove protective covers from all connections.

3.4 Valves must only be installed where 'weld neck' flanges are used. Other flange types may restrict

operation.

3.5 Disc check valves simply fit between two pipe flanges (see Fig. 2). Standard gaskets are used either

side of the valve together with longer bolts or studs. Note: flanges, bolts (or studs), nuts and joint

gaskets to be provided by the installer. Normal sensible flange bolting practice should be followed

eg. torque tightening the bolts in opposite sequence.

3.6 The DCV1, DCV3 and DCV3LT can be installed in any plane with the exception of DCV's supplied

without an internal spring. These must be fitted in a vertical flow line with the flow from bottom-to-

top i.e. upward flow (see Fig. 2b). Disc check valves must be fitted in accordance with the direction

of the flow arrow on the body, indicating correct fluid flow direction.

Note: Disc check valves are not suitable for use where heavily pulsating flow exists, such as close to a

compressor.

Fig. 2

a b c

'b' is the only acceptable

orientation when a DCV is supplied

without an internal spring

3. Installation

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