Var MATIC: Design And Selection Criteria of Check Valves VAL-MATIC VALVE AND MANUFACTURING CORP. 905 RIVERSIDE DR. + ELMHURST, IL. 60126 TEL. 630/941-7600 + FAX. 630/941-8042 Copyright © 1993 Val-Matic Valve and Manufacturing CorporationFORWARD Design And Selection Criteria Of Check Valves was written to assist the engineer or user when selecting a check valve for a given application. It is not intended as a paper on the cause and effect of water hammer, surges or headloss. There are many excellent papers and books available today covering these subjects. Nor is it intended to pass judgement on the quality or performance of any one type of check valve or check valve manufacturer. Rather, it attempts to identify the criteria which should be considered and helps the reader weigh their importance when selecting a check valve.In. III. Iv VI. TABLE OF CONTENTS Introduction Selection Criteria Non-Slamming Characteristics A. Closing Time 1. Rapid Closure a. Velocity of Reverse Flow b, Mechanical Assistance c. Length of Disc Stroke 2. Slow Closure B. Disc Travel Headloss A. Reducing Headloss Through Design 1. Body Design 2. Disc Design Cost A. Energy Consumption B. Maintenance Costs SelectionDESIGN AND SELECTION CRITERIA OF CHECK VALVES Introduction “The swing check still has a large portion of the check valve market, although there are many other types of check valves that are an improvement over the swing.” Ronald C. Merrick P.E., Valve Selection and Specification Guide (New York, Van Norstrand Reinhold Press, 1991) Page 259 Few written statements about check valves have been as true or understated as Mr. Merrick’s. Eighty years ago the specifier had only to pull out a standard swing check specification and add it to the system plans regardless of location, regardless of application. Today, with the increased demand for efficiency and dependability, the engineer must exercise greater care in making a selection from the broad range of choices available. But which valve should be chosen for a given application? The following has been developed to assist the engineer in identifying and defining the criteria for selecting a check valve.II. Selection Criteria There are four concerns which should be addressed when selecting a check valve; non-slamming characteristics, headloss characteristics, cost, and application. A close interrelationship exists between the first three. It mightbe stated thusly: consider three parts which equal a whole where x = headloss characteristics, y = non-slamming characteristics and z = cost. x+y +z = 100 In the equation if you add to x, an equal amount must be subtracted from y or z or a combination thereof. Check valve design is, as a rule of thumb, similar to the equation. The design engineer has two approaches; 1.) design a valve which takes all three into equal consideration or 2.) place emphasis on one or two of the criteria. By taking both approaches a variety of valve designs become available enabling the specifier to choose a valve tailored to the fourth selection criteria, application. Having a good understanding of each of the criteria will help the specifier choose the best valve for a given application.III, Non-Slamming Characteristics There are two major criteria which affect a check valves potential for slamming and creating surges. One is the amount of time it takes the valve to close. The second is the way in which the disc travels from the open to the closed position. A. Closing Time When a pump shuts down, the forward momentum, or velocity of the flow diminishes. When the forward flow stops, a reverse flow will begin. Depending on system conditions, the reversal can happen quickly with rapid increases in velocity occurring. The longer the reverse flow is allowed to go unabated, the more momentum (velocity) it will build. If the reverse flow is 1.) allowed to build momentum and 2.) suddenly stopped, slamming (water hammer) will occur with a resultant pressure surge. To avoid contributing to slamming and surges a check valve must close very rapidly or very slowly. If closed fast enough, a check valve can virtually eliminate reverse flow, keeping slamming and surges to a minimum. Silent Check valves are known for their ability to do so. More often, a rapid closing check valve does not eliminate reverse flow but keeps the momentum (velocity) to a minimum, thereby minimizing the slam and surge. Closing the valve slowly allows the reverse flow to build momentum but avoids a sudden stoppage. Once again, this will minimize slamming and the accompanying surge.Rapid Closure Three factors will impact the speed at which a check valve closes. The first is the velocity of the reverse flow. The second is the use of mechanical assistance through springs, weights and levers, cushions, etc. The third is the length of the disc’s stroke, or how far the disc must travel to reach the closed position. + Velocity of Reverse Flow As indicated previously, it is inadvisable to allow the reverse flow to close the valve as slamming and surges will occur. If slamming and surges are a concern this is precisely the situation to avoid. b. Mechanical Assistance Rapid closure of a check valve can be achieved through the use of springs, weights and levers etc. Two types of check valves, silent checks and dual disc (sometimes called a double door), included springs in their original designs. Springs, weights and levers, etc. were added to swing checks over the years as a way to overcome the valves propensity to slam. The use of mechanical assistance to close a valve rapidly will, to a varying degree, depending on the valve, succeed. However, it is often done at the expense of efficiency as turbulence andNotes: headloss are increased, sometimes significantly. Length of Disc Stroke The length of the disc stroke or how far the disc must travel to reach the closed position is of particular importance. Obviously, the shorter the stroke the faster the valve will close. Valves with discs designed to travel in a linear motion* (Silent Check Valves) typically provide a short stroke. The length of stroke can vary from 35° to 90° on valves with a non-linear’ stroke. A shorter stroke on a nonlinear valve is usually achieved by placing the seat on a 45°-55° angle shortening the distance the disc must travel to reach it. If the body geometry is designed to provide full flow coupled with a non-turbulent path, this design will provide a good combination of non-slamming characteristics and low head loss. Slow Closure As stated previously, a valve designed for slow closing will allow the momentum (velocity) of the reverse flow to build. In this scenario, the speed at which the valve closes is calculated and See disc travel, Page 10.controlled to avoid slamming and surges. In many circumstances it is necessary to control only the final 10% of the disc travel. Naturally, the length of the disc stroke will affect the speed as with the rapid closing valve. There are several ways to control the closing speed of a slow closing check valve. Dashpots, oil accumulators, cushions, and power actuators are just a few. The specifier should work closely with the valve manufacturer to determine the best valve and method of control to utilize. Disc Travel There are two basic ways in which a check valve disc travels. The most common is a nonlinear motion. The second is a linear motion. Check valves utilizing a nonlinear motion have a pivot from which the disc swings or rocks. The pivot is located at the top (Swing Flex, Swing Check), center (Dual Disc), or eccentrically offset (Tilted Disc). A check valve utilizing a linear design (Silent Check Valve) places the disc in-line with the seat. The disc travels in a straight line from the open to closed positions. In a check valve whose disc travel is linear, the percent of flow area will be equal to the percent of travel of the disc. Percent Open = Percent of Flow Area If the valve disc is open 5% the flow area through the seat will also be 5%. 10As the valve reaches its closed position there is minimal reverse flow present to slam the valve closed. Now consider a valve with a nonlinear stroke. In nonlinear designs, disc position is not equal to flow area. This particularly true in the final stages of disc travel prior to closure. With the disc at 5% open the flow area could still be as high as 20-30%. This means that at closure a reverse flow of large volume is still present and will slam the valve closed with significant force. In summary, it could be stated that length of disc travel plus type of disc travel equals a check valves potential to slam. 1Iv. Headloss There are two givens regarding headloss. First, all check valves create headloss and second, headloss costs the user money through increased power consumption by pumps. The importance of headloss varies. In a pressurized distribution system it’s an issue of considerable concern. In a gravity waste water collection system it may be of little concern. A. Reducing Headloss Through Design Three design factors will impact the amount of headloss created by the valve. They are total flow area through the body, body geometry and how the disc interacts with the flow. 1. Body Design To avoid headloss the total valve body area, minus the internal components, should be equal to, or slightly greater than, the mating pipe diameter. Body geometry is equally important. A design which creates turbulence in the flow will in turn generate headloss. The design should avoid abrupt changes in flow direction and the body should have a contour which allows the flow to take as straight and smooth a path as possible. Extended or globe style bodies are especially beneficial as they return the flow to normal in a gradual manner. 2. Disc Design Headloss and a check valve disc is somewhat like the old cliche about real estate; Location, Location, 12Location. If the disc is located in the flow it will create headloss. As discussed on Page 5 under rapid closing, springs, weights and levers etc. will improve a valves non- slamming characteristics. However, it is done at the expense of headloss. Placing a lever and weight and/ or spring on a swing check valve forces the disc into the flow, creating turbulence and headloss. If slamming and headloss are of concern and a swing type valve is desired, it would be better to shorten the stroke by placing the seat on a 45° angle (Swing Flex) instead of the typical 90° angle. This will allow the disc to ride above the flow instead of being forced into it while supplying good non-slam characteristics. If a silent check valve is selected for its superior non-slam characteristics the specifier should consider the body design as discussed on Page Eleven, Number One. Is the body expanded to allow for full flow? Is it contoured to provide minimal turbulence? As one can see, there are trade-offs to be made when selecting check valves. The specifier must weigh the importance of each selection criteria and make an informed selection on the type of valve best suited for the application. Once selected, it is necessary to review the designs of the various manufacturers to be assured of getting the best valve possible. 13Cost The specifier must look not only at the initial purchase price but two other factors as well, the cost of energy consumption by pumps due to headloss and maintenance costs. A. Energy Consumption It is a simple matter to compare the headloss of two check valves and compute the difference in energy savings and dollars. A lower headloss valve will probably cost more to purchase. However, the difference in cost is often realized within a year or two by the savings in energy consumption. From that point on it will pay dividends on a daily basis. B. Maintenance Costs System downtime, valve location and the cost of parts and labor should all be considered. Saving a few dollars on the initial purchase can lead to the loss of thousands if a backhoe has to be brought in to dig up a valve or a critical system has to be shut down. 14VI. Selection Use of the following Check Valve Comparative Selection Chart coupled with an understanding of the criteria will provide you with a way to make an informed selection. Valve Silent Silent Tilted Tilted Tilted Swing Flex Check Valve Check Valve (Wafer! Check Valve (Globe) Disc Check Valve Disc Check Valve w/BMDP Disc Check Valve w/TMDP Swing Check Swing Check w/Lever & Weight Swing Check w/Lever & Spring Swing Check w/Lever & Weight & Air Cushion NOTES: 9 8 1 1 2 Dual Disc Check Valve 4 5 3 7 6 7 1.) 2.) 3.) CHECK VALVE COMPARATIVE’ SELECTION CHART Headloss Slamming Comparative Comparative Rating = Rating’ aovr68ee Ur NEE The ratings do not reflect quality. They simply reflect a valve types relative headloss and slamming characteristics when compared to others. The ratings do not reflect a particular manufacture but rather a generic type of valve. The valve with the least headloss was rated at one, the highest at nine. All others were given relative positions between one and nine. The valve with the best non-slam characteristics was rated at one, the worst at nine, All others were given relative positions between one and nine. 15INSTRUCTIONS Select from the Check Valve Comparative Selection Chart those valves recommended for the application. Plot the selected valves coordinates on the graph. The valve plotted closest to the bottom left hand corner will offer the best combination of low headloss characteristics and non-slamming characteristics. If one characteristic is more important than the other, you may wish to make a different selection. The chart will show what is being sacrificed to make the alternative selection. Next, consider the cost. Write in the cost of each valve next to its plotted coordinates. If the selection you made in Number Four is within your budget you are all set. If not, you may want to choose an alternate. CAUTION: Remember, the higher the headloss of the valve selected the higher your pumping costs will be. You must consider both purchase and operating costs when making a selection. 16HEAD LOSS CHARACTERISTICS Excellent CHECK VALVE COMPARATIVE SELECTION CHART Excellent Poor NON-SLAM CHARACTERISTICS NOTE: DATA IS COMPARATIVE. A VALVE WITH A HEADLOSS READING OF 6 SHOULD NOT BE CONSTRUED AS HAVING TWICE THE HEADLOSS AS A VALVE RATED AT 3.