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1348050/10
IM-P134-08
CMGT Issue 10
DCV4
Disc Check Valve
Installation and Maintenance Instructions
1. Safety information
IM-P134-08 CMGT Issue 10
2. General product information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
© Copyright 2018
Printed in GB
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1. Safety information
Safe operation of this product can only be guaranteed if it is 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 product is suitable for the intended use/application.
The product listed below complies with the requirements of the Pressure Equipment Directive
(PED) and carr ies the mark when so required. The product falls within the following P ressure
Equipment Directive categories:
Product
DN15 - DN25 SEP SEP SEP SEP
DCV4
i) The product has been specifically designed for use on steam, compressed air and water/
ii) Check material suitability, pressure and temperature and their maximum and minimum values.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spira x Sarco products are not intended to withstand external stresses that may be induced by
v) Remove protection covers from all connections and protective f ilm from all na me- plates, where
DN40 2 1 SEP SEP
DN50 - DN100 2 1 2 SEP
condensate which are in Group 2 of the above mentioned Pressure Equipment Directive.
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.
any system to which they are fit ted. It is the responsibility of the installer to consid er these
stresses and take adequate precautions to minimise them.
appropriate, before installation on steam or other high temperature applications.
Group 1
Gases
Group 2
Gases
Group 1
Liquids
Group 2
Liquids
1.2 Access
Ensure safe access and if necessary a safe wor king platform (suitably guarded) before attempting
to work on the product. Arrange suitable lifting gear i f required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipelin e at some previous time.
Consider: flammable materials, substances hazardous to health, extremes of temperature.
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1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pit s), 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 wor k proposed. Will any proposed act ion (e.g.
closing isolation valves, elect rical 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 danger of burns and consider
whether protective clothing (including safety glasses) are 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 hydrof luoric acid. Avoid skin contact and inhalation of any fumes
as the acid will cause d eep skin burns and da mage the respiratory system.
1.9 Tools and consumables
Before star ting 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 sup ervised by a suitably competent person.
Installation and operating personnel should be t rained 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 th ere is no such
system, it is recommended that a responsible person should know what work is going on and, where
necessar y, arrange to have an assistant whose p rima ry responsibility is safet y.
Post 'warning notices' if necessary.
1.12 Handling
Manual handling of la rge and/or heavy products may present a risk of injur y. Lift ing, pushing,
pulling, car rying or suppor ting a load by bodily force can cause injur y par ticularly to the back.
You are advised to assess the risks taking into account the task, the individual, the load and t he
working environment and use the appropriate handling method depending on the circumstances
of the work being done.
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1.13 Residual hazards
In normal use the external surface of t he product may be ver y hot. If used at the maximum
permitted operating conditions the surface temperature of some products may reach temperatures
of 400 °C (752 °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 b e made to protect products which are not self- draining against frost damag e in
environments where they may be exposed to temperatures below freezing point.
1.15 Disposal
Unless otherwise stated in the Inst allation and Maintenance Instructions, thi s product is recyclable
and no ecological ha zard is anticipated with its disposal providing due care is taken. However, if
the valve is fitted with a Vi ton or PTFE seat , special care must be taken to avoid potential health
hazards associated with decomposition/burning of these seats.
Viton:
Can be landfilled, when in compliance with National and Local regulations.
-
Can be inciner ated, but a scrubber must be used to remove Hydrogen Fluoride, which is evolved
-
from the product and with compliance to National and Local regulations.
Is insoluable in aquatic media.
-
1.16 Returning products
Custom ers and stockists are reminded that under EC Health, Safety and Environment Law,
when returning products to Spirax Sarco they must provide information on any ha zards and the
precautions to be taken due to contamination residues or mechanical damage which may present a
healt h, safety or environmental risk. This information must be provided in wr iting including Health
and Safety data sheets relating to any substances id entified as hazardous or potentially ha zardous.
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2. General product information
2.1 General description
The DCV4 stainless steel disc check valve is of the wafer patter n designed to be sandwiched between ASME
flanges. It is suitable for use on a wide range of f luids for applications in proc ess lines, hot water systems,
steam and condensate systems etc. Face-to-face dimensions conform to EN 558 part 2, Series 52.
As standard the valves will be supplied with a metal-to -met al seat for use on steam applic ations. Where
they are being used on oil, air, gas and water applications, alternative seat material is available - see
Section 2.5.
Standards
This product fully complies with the requirements of the Pressure Equipment Directive (PED).
Standard shut-off
Standard valves conform to EN 12266 -1 rate E.
Valves conforming to EN 12266 -1 rate D are available on request.
Soft seated versions meet EN 12266 -1 rate A, providing a differential pressure exists.
Certification
This product is available with cer tification to EN 10204 3.1.
Note: All cer tification/inspection requirements must be stated at the time of order placement.
Note: For additional product information see Technical Information Sheet TI-P144-01-EN-ISS1.
2.2 Sizes and pipe connections
DN15, DN20, DN25, DN40, DN50, DN80 and DN100.
Suitable for installation between ASME 150 or ASME 300 flanges.
2.3 Optional extras
High temperature springs for temperatures up to 40 0 °C (752 °F).
Viton soft seats for oils and gas applic ations.
EPDM sof t seat s for water applications.
IM-P134-08 CMGT Issue 10
Fig. 1
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2.4 Materials
Part Material
Body Austenitic stainless steel
Disc Austenitic stainless steel
Spring retainer Austenitic stainless steel
Standard spring Austenitic stainless steel
High temperature spring Nickel alloy
2.5 Seating options
The valves are stamped to identif y the internals fitted:
'N' - High temperature spring - Metal disc seat
'W' - Without spring - Metal disc seat
'V' - Standard spring - Viton disc seat
'E' - Standard spring - EPDM disc seat
'WV' - Without spring - Viton disc seat
'WE' - Without spring - EPDM disc seat
'T' - Valves tested to EN 12266 -1 Rate D
No identification indicates a standard spring with a metal disc.
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2.6 Pressure/temperature limits
Pressure psi g
A
E
Temperature °C
The product must not be used in this region.
A-B-D High temperature spring and without spring.
E-C-D Standard spring.
Please note: The f igures 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 c hosen.
Body design conditions for saturated steam service ASME 300
PMA Maximum allowable pressure 49 bar g @ 37 °C (710 psi g @ 98 °F)
TMA Maximum allowable temperature 400 °C @ 29 bar g (752 °F @ 420 psi g)
Minimum allowable temperature -29 °C (-20 °F)
PMO
TMO
Minimum operating temperature
Note: For lower operating temperatures consult Spirax Sarco
Temperature limits
Designed for a maximum cold hydraulic test pressure of 76 bar g (1 102 psi g)
Maximum operating pressure for saturated steam
service
Maximum operating
temperature
Steam
saturation
curve
Standard spring 300 °C @ 31.5 bar g (572 °F @ 457 psi g)
High temperature spring 400 °C @ 29 bar g (752 °F @ 420 psi g)
Without spring 400 °C @ 29 bar g (752 °F @ 420 psi g)
Viton seat -25 °C to +205 °C (-13 °F to +401 °F)
EPDM seat -40 °C to +120 °C (-4 0 °F to +248 °F)
B
Pressure bar g
C
D
49 bar g @ 37 °C (710 psi g @ 98 °F)
-29 °C (-20. 2 °F)
Temperature °F
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2.7 Body marking information
Fig. 2
Rolled body markings and description
DN15
DCV4
ASME 30 0
A351
CF3M
Made in
France
BS 743 8
A B C D E F G H I
DNX
DCV4
Flow
direction
Design
pressure
Materi al
standard
+
Grade
Countr y of
manufacture
Standard
applicable
Melt
number
Identity of
Foundry
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3. Installation
Note: Before ac tioning 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:
Check materials, pressure and temperature and their maximum values. If the maximum operating
3.1
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.
Determine the correct installation situation and the direction of fluid flow.
3.2
Remove protection covers from all connections and protective film from all name-plates, where
3.3
appropriate, before installation on steam or other high temperature applications.
Valves must only be installed where 'weld neck' f langes are used. Other f lange t ypes may restrict
3.4
operation.
Disc check valves simply fit between two pipe flanges (see Figure 3). Standard gaskets are used
3.5
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 e.g. torque tightening the bolts in opposite sequence.
The DCV4 can be fitted betwen ASME 150 or 300 f langes. They can be installed in any plane with
3.6
the exception of DCV 's supplied without an internal spring. These must be fitted in a ver tical flow
line with the flow from bot tom-to-top i.e. upward flow (see Figure 3b). Disc check valves must be
fitted in accordance with the direction of the f low arrow on the body, indicating correct f luid f low
direction.
Note: Disc check valves are not suitable for use where heavily pulsating flow exists, such as close to a
compressor.
a b
d
Fig. 3
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c
'b' is the only acceptable
orientation when a DCV is supplied without an internal
spring
e
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4. Commissioning
After installation or maintenance ensure that the system is fully functional. Carry out tests on any alarms or
protective devices.
5. Operation
Disc check valves are opened by the pressure of the fluid and closed by the spring as soon as the flow ceases
and before the reverse flow occurs.
Open Closed
Fig. 4
Kv values
DN 15 20 25 40 50 80 100
K
v
For conversion:
Cv (UK) = Kv x 0.963
Cv (US) = Kv x 1.15 6
4.4 7. 5 12 26 39 84 150
Opening pressures in mbar
Differential pressures with zero flow for standard and high temperature springs.
Flow direction
DN 15 20 25 40 50 80 100
Where lowest opening pressures are required, valves without springs can be installed in vertical pipes with
bottom-to -top flow.
Without spring
10
25 25 25 28 29 31 33
22.5 22.5 22.5 24 24.5 25.5 26.5
20 20 20 20 20 20 20
2.5 2.5 2.5 4.0 4.5 5.5 6.5
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6. Maintenance
Note: Before ac tioning any maintenance progr amme o bser ve the 'Safety information' in Section 1.
This product is non-maintainable.
Note: Great care must be taken if a DCV with a heavy dut y spring is taken apart since the strength of the
spring c an cause the retainer to spring out of the body.
7. Spare parts
There are no spare parts available for this product.
How to order a new product
Example:
1 off Spirax Sarco DN25, DCV4 stainless steel disc check valve for fitting between ASME 150 flanges.
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