PT.

Antogus Bona Sere (ABS)

4. Check Valves
4.1 Introduction to Check Valves
4.1.1 Definition of Check Valves
 Check valves (also known as nonreturn valves) are automatic valves that prevent a return or reverse flow of the
process. Check valves are unique in that they do not require an outside power supply or a signal to operate.
Rather, the check valve's operation is dependent upon the flow direction of the process, which may be created by a
pump or a pressure drop. If the flow stops or if pressure conditions change so that flow begins to move backward,
the check valve's closure element moves with the reverse flow until it is seated, preventing at backward flow. The
check valve remains closed until positive flow direction is again achieved, at which time it opens with the flow
direction and remains open as long as the flow continues.
 Although the primary purpose of check valves is to prevent fluid backflow, its shutoff tightness is dependent upon
the reverse pressure drop, where the downstream pressure exceeds the upstream pressure. The larger this
reverse pressure drop, the greater the downstream pressure will push against the closure element providing better
shut- off. When the backflow is slight, the minimal pressure drop provides poorer shutoff.
 The lift check valve uses a free-moving closure element (similar to a globe valve's plug head without a stem) that
is placed above the seat. The swing check valve uses a hinged closure element that is similar to a common door
arrangement (where the hinged area is located outside the seating area). The tilting disk check valve has a
closure element much like a butterfly disk that has two pivot points located on each side of the seat.
4.1.2 Common Check-Valve Applications
 Check valves are used for two main purposes: first, to prevent back- flow, and second, to maintain
pressure. Check valves are oftentimes installed in a process system to maintain pressure in a line after a system
pump has stopped or failed.
 Check valves are also important in the correct function of compressors and reciprocating pumps. Check valves
may be a requirement for secondary systems where pressures can exceed that of a primary system. They also
prevent any damage associated with reversal of rotary pumps and compressors.
 If a system is apt to pulsate or create some fluctuations, the check valve is commonly placed as far away as
possible from the portion of the system causing the fluctuations. If the check valve is installed close to the source of
the fluctuations, it could further aggravate the situation by continually opening and closing, increasing the
magnitude of the fluctuation, and causing wear on the moving parts and seating surfaces of the valve. A
nonslamming check valve has a tendency to dampen pulsating flow and can sometimes be placed close to the
source for that purpose.
2
 Nonslam designs aside, the speed by which the closure element closes is often a measurement of the distance between
the full-open and full-closed position of the closure element. In most cases, this is a function of the size of the check valve:
the smaller the closure element, the smaller the travel from open to closed. Therefore, in smaller-sized applications, the
check valve would be expected to close much faster than in larger-sized applications.
 Generally, check valves can be used in both horizontal and vertical pipelines, although the use of a typical check valve in
a vertical pipeline requires a spring to close the closure element (since gravity has a minimal effect on the piston, poppet,
ball, disk, etc.). In vertical pipelines, flow must always rise up under the closure element. Otherwise, the check valve would
have to have enough pressure reversal to lift the closure element into the seated position against its weight, which is
unlikely in most cases.

4.2 Lift Check Valves

4.2.1 Introduction to Lift Check Valves
 A common lift-check-valve design is the piston check valve (Fig. 4.1), which uses a globe body design with either a piston
or a ball installed above the seat. The piston is pushed up by the flow (flow-under-the-seat) until the flow reverses when
gravity and downstream pressure close the closure element against the seat. A nonslamming piston is a special design
that is vented to allow it to move slowly to the closed position. Another design variation of the lift check valve is the ball
type, which uses a spherical ball instead of a piston or poppet (Fig. 4.2).
 The linear design includes an integral seat and a cage (which is sometimes an integral part of the bonnet cap) to keep the
ball in place during flow. The advantage of using a ball as the closing device is that it can rotate with the flow, utilizing the
entire spherical surface as a seating surface to minimize wear, especially in high-cycle applications. Also, when it is
applied in viscous services or services where particulates are present, the ball is less likely to become dirty and stick. The
ball does not require venting because the chamber above the ball is never completely blocked off. Another advantage of
using the ball as the closure element is that it can be designed exclusively for use in vertical pipelines, using a straight-
path flow body.
 The linear design includes an integral seat and a cage (which is sometimes an integral part of the bonnet cap) to keep the
ball in place during flow. The advantage of using a ball as the closing device is that it can rotate with the flow, utilizing the
entire spherical surface as a seating surface to minimize wear, especially in high-cycle applications. Also, when it is
applied in viscous services or services where particulates are present, the ball is less likely to become dirty and stick. The
ball does not require venting because the chamber above the ball is never completely blocked off. Another advantage of
using the ball as the closure element is that it can be designed exclusively for use in vertical pipelines, using a straight-
path flow body.
3
 Another common lift check valve is the plug-type design (Fig. 4.3), which uses a simple plug to lift when flow is
under the seat and to allow the downstream pressure and gravity to seat the plug quickly. Because the plug does
not require the sealing of a chamber above the plug, the tolerances between the cage or seat retainer and the
plug are not as close as the nonslamming design, allowing for smooth movement without the increased possibility
of galling or sticking. A spring can be placed above the plug to assist with closure when installed in a vertical line.
 Another variation of the plug-type check valve is the poppet-type spring check valve (or center-spring check
valve), which uses a special plug with loose tolerances (called a poppet) as the closure element. A spring is
placed behind the poppet to keep the closure element closed unless positive line pressure is applied. Unlike other
lift check valves, flow is straight through the body without any right turns.
 Poppet type spring check valves can be used in either horizontal or vertical lines, and because of their smaller
sizes [2 in (DN 50) and smaller] are available with threaded or coupled connections (Fig. 4.4). Some poppet type
spring check valves are available in larger sizes above 2 in and have flanged connections (Fig. 4.5).
 Because of the close tolerances generally associated with lift check valves, the service should be free of foreign
materials and large particulates to avoid galling or sticking. Although some seat leakage is expected with lift check
valves, the presence of large particulates may prevent adequate seating and increase the chance of leakage in
the closed position.
 Lift check valves are found in nearly all sizes and pressure classifications, from 1 to 36 in (DN 25 to DN 900) in
pressure classes between ANSI Classes 150 and 300 (PN 16 to PN 40), and in sizes from 1 to 12 in (DN 25 to DN
300) in pressure classes above ANSI Class 900 (PN 160).
4.2.2 Lift-Check-Valve Design
 In most cases, .the lift check valve uses a standard globe body with top- entry to the closure element, although
some designs use a Y-body design (Fig. 4.6). The primary advantage of using a Y-body design is that the check
valve can be used in either
 Horizontal or vertical pipelines with the same 45° orientation, although it requires the use of a spring above the
piston or plug for proper operation. As with any Y-body design, the check valve has better straight-through flow, a
larger flow rate, and a lower pressure drop than the straight-through globe valve body design.
 Depending on the design, the body may have an integral seat to allow for a maximum flow area. The trim involves
a full-area integral seat or a separate seat ring as well as a matching closure element. Three closure-element
designs are typically available: the nonslam piston, the quick closure plug (or poppet), and the ball. The nonslam
piston (again refer to Fig. 4.1) is shaped much like a pressure-balanced linear globe plug head.
4
5
 The piston is guided on a cage or seat retainer. The tolerances between the cage and the piston are reasonably
close-similar to a pressure-balanced trim design in linear globe valves-to allow for the use of piston rings.
Obviously, in larger sizes, the piston can become quite heavy and the weight alone may resist the opening of the
check valve. In this case, the weight of the piston can be reduced by machining away the middle portion of the
piston, leaving the two ends as guiding surfaces. The key element to designing any closure element of a check
valve is to balance the need for low inertia against the need for closing forces.
 To achieve movement with positive flow, low inertia is permitted through lightweight construction of the closure
element. However, it cannot be so lightweight that it does not respond well to lessening, stagnant, or reversed
flow.
 The design includes a fluid chamber placed above the piston to assist with the nonslamming mechanism, which is
sealed by the piston rings between the piston and the cage. Upon opening, flow is removed from this chamber by
a small ball check valve inside the piston. The nonslamming principle is provided by an orifice drilled into the
piston or by using a removable orifice. The size of this orifice determines the speed of closure for the piston, which
allows flow to move into the chamber at a particular flow rate. Therefore, this principle applies: the smaller the
orifice, the slower the closure. The trim is held in place and sealed by a bonnet or bonnet cap, which may be
bolted or screwed into place. Gaskets are provided between the body (or cage) and cage (or bonnet), as well as a
gasket between the seat (or body).
6
 When the check valve is placed in a horizontal line, the weight of the piston assists with the closure. However, when
the check valve is placed in a vertical line, the piston's closure cannot be assisted by gravity. In this case, a light-
duty spring is placed in the chamber. This spring is intended to generate only enough force to overcome the
cracking pressure and the friction between the piston and the cage. The spring also serves to prevent the piston
from sticking at the top of the stroke-sometimes the free-floating piston can become slightly cocked and stick to the
cage, preventing closure during flow reversal.
 The spring is also designed to help provide better shutoff, especially when the pressure differential during reversal is
slight. One drawback with a spring is that the cracking pressure may be slightly higher because the reversal flow
must also overcome the spring force.
4.2.3 Lift-Check-Valve Operation.
 Nonslamming piston-type lift check valves are always installed in the J process line with flow-under-the-piston.
 When the upstream pressure (P 1) is at a higher pressure than the downstream pressure (P 2) the flow is through
the valve, pushing the piston away from the seat and allowing full flow. As described in Sec. 4.2.2, some pistons
have a ball-type check valve in the piston to relieve the fluid above the piston. The opening speed of the piston is
dependent on the orifice size of the piston's check valve: the larger the orifice, the faster the opening of the piston.
In most piston-type lift check valves, the orifice of the ball check valve is as large as possible for quick opening.
 If the flow ceases movement or if it reverses direction (the down- stream pressure exceeds the upstream pressure),
the weight of the piston-or spring force if the valve is installed vertically-causes it to move toward the seat.
 As the piston begins to drop, the ball check valve in the piston closes with the flow reversal. As the piston drops, the
pressure in the chamber above the piston decreases. Without an outlet the chamber would achieve vacuum, which
would prevent the piston from moving at all.
 The higher fluid pressure on the opposite side of the piston causes flow to move into the chamber above the piston,
although its flow rate is limited by the size of the limiting orifice. As the flow moves into the chamber, the piston
drops slowly until it finally seats. The seat tightness blocks the flow, but provides only limited shutoff unless the
downstream pressure is significantly higher than the upstream pressure.
 When the flow reversal ends, or if the upstream pressure exceeds the downstream pressure, the piston opens at a
predetermined cracking pressure between the two sides of pressure. With pulsating or fluctuating flow, a nonslam
piston check valve is continually moving toward or away from the seat with pulses of flow. However, because of the
limiting orifice, the piston cannot move as quickly with the pulses, which allows the valve to modify the flow.
7
 As with nonslam piston check valves, the plug-type check valve is installed with the flow under the plug and in
principal works with the same pressure differentials.
 The only difference is that no chamber exists above the plug to prevent the plug's weight (or spring) from quickly
closing the valve. For this reason, the plug-type check valve is used for services where closure must take place
immediately. With ball-type check valves, the flow direction is flow-under-the-ball, using the same flow principle as
plug-type check valves.
4.2.4 Lift-Check-Valve Installation.
 Larger lift check valves, 3 in (DN 80) and larger, should be lifted into position using a mechanical hoist and straps
to avoid personal injury or equipment damage. Ideally, a lift check valve should be installed five pipe diameters
away from any source of process turbulence to avoid flutter of the closure element, which can dramatically
increase valve wear. If five diameters are not possible, the user should place the valve as far away as possible
from the source. If the valve is installed in a vertical line, the user should ensure that the design includes a spring
behind the piston or plug to ensure proper closing operation. Special precautions should be taken to ensure that
the lift check valve is installed in the correct direction.
 A flow tag or cast arrow is indicated on the side of the check valve. If the valve is installed in the wrong direction,
positive flow will keep the valve shut.
 Because of the close tolerances associated with both piston and plug styles, the user should ensure that no foreign
material is included in. the valve or on either side of the piping that may lead to sticking, galling, or increased
leakage during operation.
 Once the check valve is installed in the process line, the valve should be soon checked for proper operation. First,
the entire line should be pressurized. The upstream pressure is then drained off until the downstream pressure is
greater than the upstream pressure and the check valve closes. Typically, horizontally mounted lift check-valves
close when the upstream pressure is 1 psi (0.1 bar) less than the downstream pressure. If a non slamming piston
is used, the valve should close a few seconds after the pressure reversal has occurred. If a new valve closes too
soon or too late, a different limiting orifice may be used to speed up or slow down the valve's closing.
 After the valve has closed, the user should increase the upstream pressure until it is higher than the downstream
pressure. When the cracking pressure is reached, the valve should open.

8
4.2.5 Lift-Cheek-Valve Troubleshooting.
 If possible, the upstream pipeline should be depressurized until the valve closes. The system should then be re-
pressurized until the valve opens at the correct cracking pressure. If the check valve fails to close or open or if
notable leakage is occurring, the piston, plug, or poppet may be sticking, the seat ring may be out of alignment, or the
seating surfaces may be dirty or damaged. In this case, the lift check valve will need to be disassembled and
repaired. The user should visually check the end connections and around the bonnet or bonnet cap for signs of
process leakage. If leakage is occurring, the check valve needs to be disassembled to replace the gaskets.
 If a non slam piston design is being used, the closure speed should be checked to make sure it has not changed
drastically. An increased closing speed may indicate either worn piston rings (allowing flow to escape through the
rings) or a stuck-open ball check valve in the piston itself. If the valve is closing too slowly, the most likely cause is
contamination buildup inside or around the limiting orifice.
4.2.6 Lift-Check-Valve Servicing
 Before disassembling the lift check valve, the process fluid should be drained from the valve and the pipeline
depressurized to atmospheric pressure. If the valve was used in a caustic fluid, it may need to be decontaminated
before servicing proceeds. After removing the bonnet-flange bolting, the bonnet cap and gasket should be lifted off
the top of the body. If included, the spring should be removed, followed by the cage or seat retainer, piston or poppet,
and seat ring. The user should examine the cage or seat retainer and piston or poppet, looking for indications of
galling or scoring between the two parts. Unless the damage is very minor, worn or scratched sliding surfaces usually
require new parts.
 If a non slamming piston is used, the ball check valve should be disassembled. The limiting orifice should be cleaned
thoroughly of any process or dirt buildup. The piston rings should be checked for damage or unusual wear. The
seating surfaces of the seat ring and the piston or poppet should be checked to ensure an adequate seal. If the
seating surface is damaged or worn, re-machining the seat angles may help avoid replacement for the time being.
 If the seat angles are re-machined, the original angle should be maintained. If an integral seat is used in lieu of a seat
ring, machining that surface may be extremely difficult and may best be left to a valve repair facility.
 The overall body should also be inspected for process damage. Areas of severe corrosion should be blasted and
repainted. After all parts have been thoroughly inspected and cleaned, as well as repaired or replaced if necessary,
the lift check valve should be reassembled in the reverse order as the parts were removed during disassembly. All
gaskets should be replaced during this process. The user should make sure that the piston or plug moves freely
inside the cage or seat retainer and that the piston or plug makes full contact with the seating surface. 9
 After the internal parts have been replaced, the bonnet cap should be reinstalled and the body bolting tightened,
using the correct tightening method (and torque values if applicable). Insufficient bolting tightness will result in
inadequate gasket compression and will lead to process leakage. Once the check valve is reassembled, the user
should check for correct operation by proceeding through the process described in Sec. 4.2.4.

4.3 Swing Check Valves

4.3.1 Introduction to Swing Check Valves
 One of the more simple check valve designs is the swing check valve, which uses a hinged door to open during
positive flow and to close against a pressure reversal (Fig. 4.7).
 From outside appearances, the body used with the swing check valve appears similar to a globe-style body,
although it actually has a straight-through flow path rather than flow under (or over) the closure element. The body
is usually top-entry and uses standard end connections. Although the face-to-face is typically longer than a gate
valve, it is shorter than a globe valves face-to-face.
 The basic advantage of using the swing check valve is its design simplicity. Other than an occasional problem
with binding between the pin and the disk arm, little else can go wrong. Even if particulates are present in the flow
stream and become caught between the disk and the seat, when the valve opens the offending matter flows
down-stream. The primary disadvantage is that swing check valves are best utilized in lower-pressure classes
(ANSI 150 to 600 or PN 16 to PN 100). In higher-pressure classes, the disk must be made with a greater wall
thickness. This greater mass and weight make it harder for the disk to swing open as well as to produce some
slamming when flow reverses.
 Generally, this pressure weight issue precludes the use of swing check valves in pressure classes higher than
ANSI Class 900 or PN 160. Swing check valves are normally found in sizes from 1 to 36 in (DN 25 to DN 900),
although most are less than 12 in (DN 300) in size.

4.3.2 Swing-Check-Valve Design

 The closure element is normally a round disk and a seat, which can be a separate part or integral to the body. The
disk has an integral arm that is attached to a pivoting hinge pin. To avoid the design and manufacturing difficulties
of attaching the hinge pin directly to the body, an internal hanger is used to attach the hinge pin to the disk arm.
10
 The hanger can be attached to the body directly or to the bottom of the bonnet cap. Attaching the hanger to the
bonnet cap has the added advantage of being able to adjust the alignment of the disk and seat. The seating
surfaces of both the seat and the disk are flat and make full contact when seated. The area of contact can be narrow
or broad, depending on the manufacturer's design.
 The bonnet cap, which is used to seal the top-entry portion of the body, can include an integral disk-stop. This disk
stop is used to limit the swing of the disk at a certain angle (normally 60° to 85° from the centerline of the pipe). With
the disk-stop, the disk remains in the flow stream and is subject to instant closing when the flow stops or reverses.
4.3.3 Swing-Check-Valve Operation
 When the upstream pressure (P1) exceeds the downstream pressure (P2) the flow moves through the seat and
against the disk, causing it to move in the same direction as the flow. As the positive flow increases, the flow pushes
the disk farther away from the flow path until the disk is nearly out of the flow stream. At this point the disk-stop, if
used in the design, stops the swing travel of the disk.
 As the flow lessens, the weight of the disk allows it to drop until the drag of the flow prevents it from traveling any
further. If the flow stops, the weight of the disk allows it to drop down until its seating surface makes contact with the
seat. If the flow reverses, the greater downstream pressure, P2 pushes the disk toward the seat, improving the
shutoff. The leakage during shutoff depends on the reverse pressure differential: the greater the reverse pressure
differential, the better the shutoff. The disk remains in the closed position until a positive flow is again achieved and
the cracking pressure is reached, allowing for the disk to again begin swinging open.
4.3.4 Swing-Cheek-Valve Installation
 To avoid personal injury or damaging the equipment, swing check valves larger than 2 in (DN 50) should be lifted
into position using a mechanical hoist and straps. Ideally, a swing check valve should be installed five pipe
diameters away from any source of process turbulence to avoid check valve flutter, which can dramatically increase
valve wear. If five diameters are not possible, the user should place the valve as far away as possible from the
turbulent source.
 For correct operation, the user should make sure that the swing check valve is installed in the correct direction by
visually checking the flow tag or cast arrow on the side of the check valve. If the valve is installed incorrectly,
positive flow will keep the valve closed. To avoid any damage to the seating surfaces or binding of the hinge pin,
foreign material (such as welding rods, scale, etc.) should be cleaned from both sides of the piping. Before installing
the valve in the line, the disk should be checked to make sure it moves freely without binding or sticking. The user
should not use his or her hands to do this, since some disks are heavy with sharp edges, which may pinch or cut
fingers.
11
 Once the swing check valve is installed, the entire line should be pressurized to operating conditions. Proper
function of the check valve can be quickly checked by draining off the upstream pressure until the downstream
pressure is- greater than the upstream pressure and the valve shuts off with the reserve flow. Typically,
horizontally mounted lift check valves close when the upstream pressure is 1 psi (0.1 bar) less than the
downstream pressure. After the valve has closed, the upstream pressure should be increased until it is higher
than the downstream pressure. When the cracking pressure is reached, the valve should open.
4.3.5 Swing-Check-Valve Troubleshooting
 If the system permits, the upstream pipeline should be depressurized until the valve closes, followed by re-
pressurization until the valve opens at the cracking pressure. If the check valve fails to open or close, or if
notable leakage is occurring through the closure element, a number of causes may be possible: the hinge pin
may be sticking or galling, or the seating surfaces may be dirty or damaged. In these cases, the swinging check
valve will need to be disassembled and repaired.
 The end connections and the gap between the body and the bonnet cap should be inspected for signs of process
leakage. If leakage is occurring, the valve will need to be disassembled and the gaskets replaced. If the swing
check valve has a hinge pin that is installed through a bore in the body wall, the seal of the retainer plug should
be checked. If the valve is closing too slowly or experiencing erratic operation, the most likely cause is process
buildup around the hinge pivot point or galling between moving parts.
12
3.6 Swing-Check-Valve Servicing
 If the swing check valve is not shutting off or opening properly, it should be disassembled and repaired. Before
disassembly takes place, the pipeline should be depressurized to atmospheric pressure and the process fluid
should be drained from the valve especially if the process is caustic.
 After removing the body bolting, the bonnet cap should be lifted off the top the body. The gaskets may then be
removed. The gasket surfaces should be inspected for any signs or erosion or process leakage. The user should
test the travel of the disk to check for a smooth action. If the pivot point between the pin and the disk handle
shows signs of process build up, the buildup should be removed and cleaned until the disk moves freely. If the
pivot point continues to bind, the pivot point assembly should be disassembled and examined for signs of galling.
If a substantial galling has occurred, the damaged parts should be replaced. If minor galling has occurred, it may
be repaired using an abrasive cloth. If a retainer plug is used to seal a hinge pin bore, it should be removed prior
to removing the pin.
 The seating surfaces of the seat and the disk should be checked to ensure an adequate seal. The separable seat
is usually threaded and may require a special tool provided by the manufacturer. With all internal threading
arrangements, corrosion can pose difficulties in removing the seat without applying significant force that could
further damage the part. If the seating surfaces appear to be slightly worn or damaged, re-machining the flat
surfaces of the seat may keep the valve functioning without having to replace the seat and disk.
 The overall body should be also inspected for process damage. Areas of severe corrosion should be blasted and
repainted (if applicable). All other parts should be thoroughly inspected and cleaned. If possible, minor damage
should be repaired. Severely damaged parts, as well as all gaskets, should be replaced as standard practice.
The lift check valve should be reassembled in the reverse order as the parts were removed during disassembly.
After the pivot-pin assembly has been reassembled, the user should make sure that the disk moves freely
without too much play. Too much play in the hinge could cause chatter and premature wear; therefore the hinge
should be snug, but not too tight.
 If the hinge is too tight, sticking and premature wear will result. Some manufacturers recommend lubrication of
the hinge pin in certain applications.
 If this is the case, the lubrication must be compatible with the process. After the hinge-pin assembly is complete,
the disk should make full contact with the seat's seating surface.
13
 After the internal parts have been replaced, the bonnet cap and the body bolting should be reinstalled, using the
correct tightening method. Insufficient bolting tightness will result in inadequate gasket compression and will
likely lead to process leakage. If the bonnet cap has an internal disk-stop, the user should make sure that the
orientation is correct so that the stop and disk make full contact. Once the check valve is reassembled, the user
should check for correct operation by proceeding through the check process (Sec. 4.3.4).

4.4 Tilting-Disk Check Valves

4.4.1 Introduction to Tilting-Disk Check Valves
 Similar in some respects to a swing check valve, the tilting-disk check valve uses a pivoting disk as the closure
element, except the pivot point is roughly through the center of the disk instead of above the disk. In many
respects, it follows the design criteria of an eccentric disk in a high-performance butterfly valve. This design
allows the disk to rotate rather than swing outward from the seat.
 The pivot point is slightly offset from the true center of the disk so that gravity can act on the disk, allowing it to
move to the closed position when neutral flow exists. However, the offset is only slight, so that a low cracking
pres- sure will open the disk and allow flow through the valve. At its full- open position, when the seat is
perpendicular to the pipe centerline, the full rotation of the disk is parallel to the centerline and 90° from the seat.
Some tilting-disk check valves are designed with the seat at a 45° angle so that the disk is only 45° from the seat
at the open position, which allows for much faster operation.
 The chief advantage of a tilting-disk check valve is its speed of closure, since the disk requires very little travel
to close. Because the pivot point is close to the center of the mass of the disk, the disk has a tendency to avoid
slamming shut (as opposed to the swing check valve), and hence is popular for use in water services where
water- hammer effects occasionally occur. The chief disadvantage is that- similar to a butterfly valve-the closure
element is in the flow stream and can generate turbulence, vibration, and noise in systems with high velocities.
Another disadvantage is maintenance, since disassembling the rotating disk is somewhat difficult as opposed to
a swinging disk. Another disadvantage with tilting-disk check valves with a split-body design is that the check
valve must be removed from the pipeline for maintenance.
 Tilting-disk check valves are normally used in large water lines-up to 48 in (DN 1200)-and are rarely seen in lines
below 4 in (DN 100). They are rated to the lower-pressure classifications of ANSI Classes 125 to 150 (PN 6 to
PN 16). Some higher-pressure designs are available but usually require some type of internal hanger to attach
the pivot pin to so as to avoid using a retaining plug in high-pressure service. 14
 Tilting-disk check valves are normally used in large water lines-up to 48 in (DN 1200)-and are rarely seen in lines
below 4 in (DN 100). They are rated to the lower-pressure classifications of ANSI Classes 125 to 150 (PN 6 to PN
16). Some higher-pressure designs are available but usually require some type of internal hanger to attach the
pivot pin to so as to avoid using a retaining plug in high-pressure service.

4.4.2 Tilting-Disk-Check-Valve Design

 The tilting-disk-check-valve design includes an integral seat inside the body, although separable seats are
available that are screwed or welded into place. The seating surfaces for the seat and the disk are beveled and
make full contact in the closed position.
 The tilting-disk-check-valve design can be achieved with either a Y- body design (Fig. 4.8) or a conventional
straight-through body design (Fig. 4.9). Normally, the pivot point is achieved using pins, which are installed
through the body wall, necessitating the use of retainer plugs to seal the body. When the straight-through or Y-
body designs are utilized, the top-entry portion of the body is sealed using a bonnet cap. The split-body accesses
all moving parts through the middle connection and does not require any top-entry access.
4.4.3 Tilting-Disk-Check-Valve Operation
 When the flow is in a neutral state (upstream pressure equals the downstream pressure), the disk has a tendency
to stay closed because of the offset pivot point. However, when the upstream pressure increases (or downstream
pressure decreases), the positive flow moves through the seat and pushes against the disk, causing it to rotate to
its open position. Because the center of the disk mass is below the pivot point, the larger half of the disk rotates
away from the flow, while the shorter half rotates into the flow. The disk continues to travel until it is stopped by
the physical limitations of the body-ideally the plane of the disk is parallel to the flow.
 As the flow slows or ceases, the dominant weight of the lower half of the disk allows it to begin dropping toward
the bottom of the seat. As the flow stops, the disk's inertia position is achieved, making seat contact. If the flow
reverses, the greater downstream pressure P 2 applies pressure to the disk in the seat, improving the shutoff. As
the reverse-pressure differential increases, shutoff improves significantly. The tilting check valve remains in the
closed position until positive flow occurs and the cracking pressure is reached or surpassed, allowing for the disk
to again begin rotating open.
15
4.4.4 Tilting-Disk-Check-Valve Installation
 Because tilting-disk check valves are 4 in (DN 100) and larger, their weight requires the use of a mechanical hoist
and straps to avoid personal injury. The best method to avoid unnecessary valve flutter is to install the tilting-disk
check valve five pipe diameters away from any source of process turbulence. If five diameters are not possible,
the valve should be placed as far away as possible from the turbulent source. As with all check valves, correct
operation is dependent upon flow orientation of the valve, which is determined by a flow tag or cast arrow on the
side of the body.
 If the valve is installed incorrectly, positive flow will keep the valve closed, while reverse flow will open the valve.
 Any type of foreign material, such as welding rods, scale, or trash, should be removed from both sides of the
piping. The inclusion of such material could damage the seating surfaces or bind the motion of the disk. Before
installing the valve in the line, the disk should be checked to see that it moves freely without binding or sticking. A
safe procedure is to use a wooden tool to move the disk, instead of one's hand, since the quick-closing motion
could catch or pinch fingers. If the disk does not move freely, the problem should be corrected before the valve is
placed in line.
 Although some tilting check valves work well in either horizontal or vertical lines, the best option for a vertical line
is a Y-body design where the disk remains in the same position (45°) despite the line orientation.
 Once the tilting-disk check valve is installed, the entire process line should be pressurized to operating conditions
and the valve should be checked. The check valve can then be tested for correct function by draining off the
upstream pressure until the downstream pressure is greater than the upstream pressure.
 At this point, the valve should shut off quickly without slamming. Typically, horizontally mounted lift check valves
close when the upstream pressure is 1 psi (0.1 bar) less than the downstream pressure. After the tilting-disk
check valve has closed against the reverse flow, the upstream pressure should be increased until it exceeds the
downstream pressure. When the cracking pressure is reached, the valve should open.
4.4.5 Tilting-Disk-Check-Valve Troubleshooting
 Periodically, the tilting-disk check valve should be checked for correct operation, similar to the procedure outlined
in Sec. 4.4.4. If possible, the upstream pipeline hold be depressurized until the valve closes, followed by
repressurization until the valve opens at the cracking pressure.

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 If flow seems restricted when positive flow is achieved, most likely the disk is not rotating freely, but is restricted in
its movement. If excessive reversal flow is noticed even after the valve should have shutoff the disk may not be
seating due to a pin that is binding or galling, or the seating surfaces may be severely damaged. In this case, the
swinging check valve will need to be disassembled and repaired.
 If the valve seems to respond sluggishly or the cracking pressure has increased significantly, the most likely cause
is a pivot pin that is bound by process buildup or galling.
 The end connections and all joints in the body, especially the retaining plugs, should be inspected for signs of
process leakage. If leakage is occurring, the valve should be disassembled and the gaskets replaced.
4.4.6 Tilting-Disk-Check-Valve Servicing.
 When the tilting-disk check valve requires service, the symptoms are failure to close against reverse flow, sluggish
response, or an increased cracking pressure.
 In all of these cases, the valve will need to be disassembled and serviced. Before any service on the valve takes
place, the line and valve should be depressurized to atmospheric pressure. If the process fluid is caustic or
corrosive, it should be drained from the valve and the valve decontaminated before the valve is worked on.
 If the check valve has a split-body design, the entire valve will need to be removed from the line for disassembly. If a
straight-through globe or Y-style body is used, the valve can stay in the line while the service is being completed
through the valve's top-entry access.
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 With split-body designs, the body bolting should be removed and the two halves separated, exposing the disk and
seat. With straight-through globe or Y-style bodies, the top-entry access can be exposed by removing the body
bolting and the bonnet or bonnet cap.
 The gaskets should be removed and all gasket surfaces should be inspected for any signs or erosion or process
leakage. The movement of the disk should be checked for ease of travel. If the pivot point shows any signs of
process buildup, it should be removed and cleaned until the disk moves freely. If the pivot point still continues to
bind, the retaining plugs (if applicable) should be removed and the pivot- point assembly disassembled. The bores
or pin should be examined for any signs of galling.
 If substantial galling has occurred, the damaged parts should be replaced, while minor galling may be repaired using
an abrasive cloth. The seating surfaces of the seat and the disk should be thoroughly examined to ensure an
adequate seal. If the seat is threaded, it should be removed using a special tool provided by the manufacturer.
 With all internal threading arrangements, corrosion can pose difficulties in removing the seat without applying
significant force that could further damage the part. If the seat is welded into place, the anchor bead weld between
the body and the seat ring will need to be ground out, being careful not to remove more material than necessary. If
the seating surfaces appear slightly worn or damaged, replacement of the parts may or may not be necessary. If the
user attempts to remachine the seating surfaces, the beveled angles of the original design should be maintained.
The overall body should also be inspected for process damage. Areas of severe corrosion should be sandblasted
and repainted.
 Before reassembly takes place, all parts should be thoroughly inspected for wear or damage and cleaned using an
appropriate cleaning solution or solvent. Any minor damage should be repaired; severely damaged parts and all
gaskets should be replaced. The check valve should be reassembled in the reverse order in which the parts were
removed during disassembly. If a separate seat is used, it should be securely tightened (if threaded) or welded.
When welding the seat into place, the welder should be careful to dissipate the heat, so that heat transfer does not
warp the seating surface of the seat ring. After the pivot-pin assembly has been reassembled, the disk should move
freely without too much play. Too much play at the pivot point can cause chatter and premature wear. If the pin
assembly is too tight, however, sticking and premature wear will result. After the assembly is complete, the disk
should make full contact with the seat's seating surface. Some manufacturers recommend lubrication of the pin in
certain applications. If lubrication is required, the lubricant should be compatible with the process.
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 After the closure element has been reassembled, the bonnet cap and the body bolting should be replaced, using the
correct tightening method (if the body is top-entry). Insufficient bolting tightness will result in inadequate gasket
compression and will likely lead to process leakage. If a split body is used, the two halves should be bolted together,
ensuring even tightness and correct gasket compression. Once the check valve is reassembled, correct operation
can be checked by proceeding through the process described in Sec. 4.4.4.
4.5 Double-Disk Check Valves
4.5.1 Introduction to Double-Disk Check Valves
 The double-disk check valve uses two half-sphere disks and a connecting hinge to create a closure element that
collapses when positive flow exists, and folds back to a full circular disk when reverse flow exists (Fig. 4.10). It is also
known as a split-disk or wafer check valve. Generally, double-check valves are popular because of their low cost
and minimal size. Their chief disadvantage is poor seal ability in low- back-pressure situations. Also, the unsealed
joint between the two half-disks allows for some backflow to move through the closure element when it is in the
closed position. The inclusion of the spring in the flow stream may present a problem if the spring fails and metal
parts are washed downstream, which may foul or damage down- stream equipment. The introduction of the closure
element into the middle of the flow stream may also present some turbulence problems with high flow rates and
velocities.
 Double-disk check valves are found in sizes 2 through 36 in (DN 50 through DN 900) in ANSI Pressure Classes 150
through 600 (PN 16 through PN 100). Larger sizes 12 in (DN 300) and higher are available only in ANSI Class 150
(PN 16).
4.5.2 Double-Disk-Check-Valve Design
 With a hinge similar to a door hinge, the two half-disks are connected using a straight pin that is inserted through a
bore in the body wall with the bore sealed by a retaining plug. At least one spring is installed in the hinge and around
the pin itself to provide a spring action toward closing, although some designs use two springs-one for each half-disk.
In some designs, a second pin is inserted just downstream from the half disks, which is used as a disk stop for the
two half-disks when they are open, as well as an anti rotation device for the spring end(s). The other spring end is
straight and lays flat against the back side of the half-disk. The springs are made from materials that provide good
spring action, as well as resistance to corrosion, such as Inconel. The spring rate can be varied by the type and
design of the spring, allowing for different cracking pressure and closing speeds. In some applications, the user may
not want the additional potential leak paths presented by the retaining plugs. In this situation, a special assembly
uses a self contained retainer to hold the pins, half-disks, and springs, which is then inserted into the body (Fig.
4.11).
19
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 In the closed position, the two halfdisks seating surfaces rest against the flat surface of an integral seat, which is
machined into the body, providing a full contact seal. The seat is perpendicular to the centerline of the pipeline.
This 90° seat is not apt to provide a strong seal with the half-disks when stagnant flow or minimal reverse flow
exists, as opposed to other check valve designs that have an inclined seat and can use the weight of the disk
against the incline to provide a tight shutoff at a low pressure differential. To compensate for this problem, a soft
seat can be specified to help achieve better shutoff at low back pressures.
 The body used for the double disk check valve is a wafer style body, which is a flat body with a minimal face-to-
face. The wafer-style body allows the check valve to be installed between two flanged piping connections with
straight-through bolting. In sizes below 12 in (DN 300) 1 and in applications where high temperatures are not a
concern, the .j wafer-style body is typically used. In larger sizes, or where high temperature may cause potential
leakage through thermal expansion, a lug-body design is used. A lug body utilizes flanges with drilled and 1
tapped holes for direct connection to flanged piping using studs and nuts. If room exists between the body's
integral flanges for nuts, tapped holes are not necessary.
 4.5.3 Double-Disk-Check-Valve Operation
 When the upstream pressure (P1) is higher than the downstream pressure (P2) the positive flow pushes against
both half doors. When the j pressure differential exceeds the spring force, the doors open with the flow and
continue to open wider as the flow increases. Finally, at full flow the half-disks reach their full motion when the
disk-stops (located on the back side of the half-disks) meet the second pin or the opposite disk stop. As the flow
lessens, the spring action begins to force the half-disks back toward their closed position. As flow stagnates, the
half-disks are in their full-closed position, with their flat seating surfaces meeting up with the flat seating surface of
the body. As reverse flow continues to build in strength, the shutoff improves.
4.5.4 Double-Disk-Check-Valve Installation
 After the double-disk check valve has been received from the manufacturer, the user should carefully inspect the
materials and spring rate to ensure its proper function in the system. Larger check valves 3 in (DN 80) and larger-
should be installed using a mechanical hoist and straps. With any large and heavy equipment, caution should be
taken to avoid dropping the valve, which may hurt personnel or damage the equipment.
 Ideally, the double-disk check valve should be installed five pipe diameters away from any source of process
turbulence to avoid check valve flutter, which can dramatically increase valve wear. If five diameters are not
possible, the user should place the valve as far away as possible from the source of turbulence. Before the check
valve is installed in the pipeline, the entire length of the upstream and down- stream piping should be checked for
any foreign materials, such as welding rods, and cleaned of scale or any other foreign material. 21
 Double-check valves can be installed in either the horizontal or vertical position. During installation, the user should
make sure that the valve is installed with the flow in the correct direction. A flow tag or a cast arrow on the external wall
of the body should indicate this. (If flow is not indicated, the open action of the door should move with the positive flow
direction).
 When installing the double-disk check valve between piping flanges, care should be taken to allow enough room for the
face-to-face of the wafer body, the width of the gaskets, and some clearance for the free movement of the valve to
slide into place. If the pipeline is rigidly fixed and too much space exists between flanges, tightening the bolting
between the piping flanges may make it hard to achieve correct gasket compression. The best installation method is to
loosely install the bottom two studs and nuts, creating a cradle for the check valve to sit.
 With the gaskets in the correct position, the remaining bolting can be installed. If the check valve has integral flanges,
they may be installed using a stud and nut for a tapped hole or a stud and two nuts for an untapped hole.
 To determine if the double-disk check valve is installed correctly and operational, both the upstream and downstream
lines must be pressurized to operating conditions. By draining off the upstream pressure until the downstream pressure
is higher than the upstream pressure, the valve should shut off quickly without a slamming. Most double- disk check
valves should close when the upstream pressure is 1 psi (0.1 bar) less than the downstream pressure. After the
double-disk check valve has closed, the upstream pressure should be increased until it again exceeds the downstream
pressure. The valve should open when the cracking pressure is reached.
4.5.5 Double-Disk-Check-Valve Troubleshooting
 As part of periodic maintenance, the double-disk check valve should be checked for correct operation. To do this, the
process system will need to be deviated from normal service by depressurizing the upstream line until the valve closes.
 Following closure, the upstream line should again be pressurized until the valve opens at the correct cracking
pressure. If the valve opens before the cracking pressure is reached or seems to flutter at a low pressure differential,
the disk spring may have failed. If flow is restricted when positive flow is achieved or if the valve seems to be sluggish
upon opening, most likely one or both double disks are not rotating freely or are binding on the pin. If excessive
reversal flow is noticed even after the valve should have shutoff, one (or both) of the half-disks may have 1 remained
opened (especially if the spring has failed). Also, the half disk may not be seating due to process binding or extensive
galling between the pin and half-disk. In this case, the double-disk check valve will need to be disassembled and
repaired.
 All potential leak paths in the body (especially the retaining plugs) should be inspected for signs of process leakage. If
leakage is occurring, the valve should be disassembled and the internal gaskets replaced. If the service has
temperature swings, the user should check for adequate tightness of the lines through bolting.

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4.5.6 Double-Disk-Check-Valve Servicing
 When the double-disk check valve fails to close against reverse flow, is sluggish in response, or has a higher
cracking pressure, the valve will need to be disassembled and serviced. However, before any service on the
valve takes place the line and valve should be depressurized to atmospheric pressure. If the process fluid is
caustic, corrosive, or dangerous to workers, it should be drained from the valve and the valve completely
decontaminated.
 Because of the wafer-body design, the piping flange bolting will need to be disassembled. With a horizontal line,
a safe procedure is to leave two bottom studs and nuts (loosened) in place so that valve does not fall during line
disassembly. Because process residue and line pressures can cause the valve to stick between the flanges, the
flanges may need to be worked loose to remove the valve. If the valve is stuck between the flanges, a crowbar or
other lever should not be used between the gasket surfaces of the flanges or valve since this may scar or indent
the serrations and make a future seal difficult.
 After the valve is taken out of the line, the gaskets should be removed from the gasket surfaces, and those
surfaces should be inspected for any signs of erosion or process leakage. The half-disks should be pushed open
using a wooden dowel. If the springs are intact, the disks should return smoothly to the closed position without
hanging up. A visual check of the springs is not enough, since a spring may be broken but may appear to be
intact. If the hinge pin shows any signs of process buildup, it should be removed and cleaned until the half-disks
move freely. If the hinge pin continues to bind, the retaining plugs should be removed and the hinge pin pushed
out. The pin, half- disk hinges, or body wall bores should be examined for any signs of galling. If substantial
galling has occurred, the affected parts (or entire valve, if necessary) should be replaced, while minor galling may
be repaired using an abrasive cloth.
 The seating surfaces of the body and the half-disks should be thoroughly examined to ensure an adequate seal.
If the seating surfaces appear slightly worn or damaged, replacement of the parts may not be necessary.
 The seating surfaces might be capable of light machining or grinding, although the user must maintain the
perpendicular flat seat surfaces of the original body and half-disks.
 The body should also be inspected for process or atmospheric dam- age. Areas of severe corrosion should be
sandblasted and repainted, if necessary. After all parts have been inspected for damage or wear, they should be
thoroughly cleaned using an appropriate cleaning solution or solvent. Any minor damage should be repaired,
while severely damaged parts and all line gaskets should be replaced.
23
 The check valve should be reassembled in the reverse order in which the parts were removed during
disassembly. The spring(s) should be correctly repositioned so that the spring ends press against the back of the
half- disks. The pin is then reinserted through the body bore and loosely retained by the body plugs. Some
manufacturers recommend lubrication of the pin in certain applications. If lubrication is required, the lubricant
must be compatible with the process. After the hinge pin has been reassembled, the disk should move freely
without too much play or tightness. Too much play can cause chatter and premature wear. If the hinge is too tight,
sticking and premature wear may occur.
 The half-disks should be visually checked to ensure that they make full contact with the body's seating surface.
After the half-disks are assembled and working smoothly, the retaining plugs should then be tightened, using the
correct torque and sealant to ensure a tight pressure retaining seal
 Using new line gaskets and two piping flange studs and nuts as a cradle, the valve should be replaced between
the piping flanges. Using studs and nuts, the flanges should be tightened with the appropriate torque value.
Insufficient bolting tightness will result in inadequate gasket compression and will likely lead to process leakage.
After or when the double-disk check valve is reassembled, correct operation should be checked by proceeding
through the process mentioned in Sec. 4.5.4.

24