Series 85 Donkin Certus Range

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1 Donkin Certus Range

2 2 Series 85 - Donkin Certus Range AVK group manufacture The AVK Group is dedicated to providing quality products which exceed local standards into the gas, water, waste water, fire protection and industrial sectors in all parts of the world. The Donkin Certus range is one product line in the extensive AVK range for the gas market. As well as these PE ball valves AVK can supply gate valves, slide valves, ball valves, non return valves, flow limitors (EFV s), under pressure tees, repair clamps, end caps, under pressure drilling machines and a wide range of accessories to suit. The Certus PE ball valves are manufactured wholly within the AVK Group. AVK UK under the Donkin Brand has utilised the core competencies of our Technical Division AVK Tech; Plastics Competence Centre AVK Plastics and world leader rubber moulding experts AVK Gummi to bring together the expertise and high quality components that have been incorporated into these valves. This brochure is a handy reference to our comprehensive range of Certus valves and related products, providing the necessary information to enable our customers to select the right product for their application. Our technical team is also available to provide product support and recommendations Manufactured and Approved to Gas Industry Standard GIS/V7: Part 2 and EN (32, 63, 90mm) Manufactured and Approved to European Standard EN and DVGW VP302 (32, 40, 50, 63, 75, 90, 110, 125, 160, 180mm) AVK Tech & Headquarters AVK Gummi AVK Plastics AVK UK Both ranges of valves are third party approved via the BSI Kitemark Scheme. All AVK products are supplied under the commitments in our Customer Service Charter and encompass the four fundamental product values of the identified in o programme: AVK Syntec QUALITY All AVK products are designed, built and 100% tested to the relevant standards. All quality processes are audited by BSI. Further information about all the products in the AVK portfolio is available on our website: RELIABILTY All AVK products are designed for a long asset life and come with a robust manufacturer s warranty. INNOVATION All AVK products are designed to give added value, reduce true life cost and utilise the most modern materials. ENVIRONMENT A full carbon reduction policy is in place allowing carbon content measurement to product level. Series 85 Donkin Certus Range

3 Series 85 - Donkin Certus Range 3 Manufacturing quality and testing The Certus PE 100 ball valves are manufactured at AVK Syntec a modern purpose built and well equipped manufacturing facility using state of the art machinery and methods to produce high quality products. Traceability is maintained throughout the whole manufacturing process from the initial injection moulding of the component parts through machining and welding and final batch release testing. Every valve is individually tested and then given a unique serial number which can be traced as far back as the raw polyethylene material. All of the manufacturing processes are managed to the exacting standards of the ISO 9001 certification. These robust PE ball valves have been extensively and independently type tested against worldwide leading standards such as GIS/V7: Part 2, EN and DVGW VP302. Full documented records of type testing are maintained by AVK and are available on request. They have also undergone additional testing over and above that required in the specification. This ensures that the valve is suitable for gas distribution systems and environments anywhere in the world. Some of the manufacturing processes involved in Donkin Certus manufacture Cap manufacture Valve body manufacture Spigot end manufacture Injection moulding Precision machining Butt fusion welding Series 85 Donkin Certus Range

4 4 Series 85 - Donkin Certus Range Examples of some of the approval tests and production tests carried out on Donkin Certus valves Extreme bending tests simulate excessive ground movement Every valve pressure tested in production Production batch tests at 80ºc Elevated temperature tests Pressure tests Torque tests Product Approvals System Approval GIS/V7: Part 2 EN DVGW VP302 ISO 9001 Series 85 Donkin Certus Range

5 Series features and benefits 5 The Donkin Certus range are a step forward in the field of PE ball valves with many advanced features which differentiate them from other valves in the market. Kitemark approval to the UK Gas Industry Standards GIS/V7: Part 2 and European Standard EN have helped them to become the market leading valve used on PE service connections in the UK. They are available direct from stock at our Chesterfield manufacturing facility, a brand new, purpose built, state of the art ISO factory. The main features of the Certus valves are listed below: (More information is available on data sheets which can be downloaded from our website Type tested and manufactured to GIS/V7 Part 2 and EN Tested and approved to two of the most searching specifications in Europe. Part of the Donkin range of valves The assurance of full technical and commercial support for the customer. Full traceability of components Ensures consistency of components meaning a top quality product. Approved via Kitemark scheme to GIS/V7 Part 2 and EN AVK safety cap If the valve is over torqued during opening or closing, the cap is designed to fail before the valve seals, thus preventing a leak to atmosphere. The cap can be replaced under live gas conditions. Yellow top cap Easily identified as a gas valve and is highly visible in a pit or chamber. Robust 50mm square drive on top cap Complies with european standards. Double length spigots The valve has double length spigots which allows a second electro-fusion joint if the first is done incorrectly. Triple O ring seal on anti blowout stem No possibility of leak to atmosphere. Manufactured from PE100 material Can be fused to PE80 or PE100. Can withstand higher pressures with thinner walled pipe. High torque design Difficult to operate without a tee key and so is less prone to unauthorised operation. Special tee key available Consistent method of valve operation. Valve has a 100% clear bore No pressure drop, greater flow through the valve for the same pressure. DN90mm and above allow for pigging of pipes. Valve access system available Cost effective method of valve installation and access can be purchased with the valve to ensure alignment for correct valve operation from the surface. Series Features and Benefits

6 6 Series installation When fitting valves it is essential that they are installed in the correct manner to ensure that when they are needed they can be operated without problem. The Donkin Certus valves have a bespoke installation kit to ensure that the valves are fitted correctly and consistently. 1 Remove valve from the bag and fit it into the base 2 unit Mark and scrape the spigot ready for fusion 3 Clamp to the pipe and electrofuse according to 4 manufacturers instruction Cut downpipe to correct length, fit to base then fit adaptor and surface box 5 Ensure surface box is fitted prior to backfilling 6 Prepare ground ready for surfacing Series Installation

7 Results of bad installation 7 Valve not fitted using correct installation kit allowed ingress of material at base which obscures spindle access. Valve fitted at an angle making fitting a tee key very difficult. Ingress of material at the base preventing full engagement with the valve top cap. Incorrect positioning of the surface box restricting access to the valve. When a valve is not fitted straight the tee key is angled resulting in possible valve damage when trying to operate. In the worst case it can result in not being able to operate the valve in an emergency situation. Series Results of Bad Installation

8 8 Accessories for certus series range As with all valves, best practice techniques should be used during installation and operation. To aid this process a series of recommended accessories are available, these include a bespoke installation and access system, extension spindle and operating tee keys. Installation kit (with or without surface box) Tee key Telescopic extension spindles 50mm to 25mm spindle adaptor REFERENCE NUMBERS (LNS) Description Reference Number MOP Specification Valves DN 32mm SDR 11 Value bar/10 bar GIS/V7: Part 2, EN DN 63mm SDR 11 Valve bar/10 bar GIS/V7: Part 2, EN DN 90mm SDR 17 Valve bar GIS/V7: Part 2 DN 90mm SDR 11 Valve bar EN Installation Kits Install Kits for 32/63mm Valves N/A Complete with Surface Box Install Kits for 32/63mm Valves N/A Excludes Surface Box Install Kit for 90mm Valves TBA N/A Complete with Surface Box Install Kit for 90mm Valves TBA N/A Excludes Surface Box Tee Keys Operating Tee Key 0.75M Long N/A 50mm Square Drive Operating Tee Key 1.0M Long N/A 50mm Square Drive Operating Tee Key 1.5M Long N/A 50mm Square Drive Extension Spindles Telescopic Extension Spindle N/A Length (0.63M M) Telescopic Extension Spindle N/A Length [0.44M M) Fixed Length Extension Spindle N/A Length M Fixed Length Extension Spindle N/A Length - 0.8M Spindle Adaptor Spindle Adaptor TBA N/A 50mm to 25mm Square Series Accessories

9 Series features and benefits 9 The new Donkin Certus are an extended range of PE Ball Valves up to 180mm which have been designed and type tested to meet the requirements of DVGW VP-302 and EN Standards. Incorporating many of the features of the range such as low operating torque and safety cap this range is more versatile as they are not only available as the standard valve but can also be obtained with welded on extension spindle and purge/ pressure points (for more information on this see page 11) dependant on the customer s requirements. Safety cap If the valve is overtorqued during opening or closing, the cap is designed to fail before the valve seals, thus preventing any leak to atmosphere. The cap can be replaced under live gas conditions. Full traceability of components Ensures consistency of components meaning a top quality product. Approved via Kitemark scheme to EN and DVGW VP-302 specifications. Valve access system available. PE 100 materials throughout PE 100 materials are used for the outer body and the internal ball and seat retainer rings. This ensures equal expansion and/or shrinkage throughout all components, thus maintaining their interfacing tolerances. Low operating torque Characterised by having a low operating torque throughout the range to avoid the use of gearboxes on larger sizes. PE 100 Ball interacting with high quality rubber seals also avoids sticking over time. Full range Sizes in the range are 32mm, 40mm, 50mm, 63mm, 75mm, 90mm, 110mm, 125mm, 160mm and 180mm. Energised seats Sealing assembly centered in the body to ensure the safe float of the ball between the seats. PE spigots Spigot ends are all SDR 11 and machined to the correct size to minimise ovality. Ends are protected with removable caps to avoid ingress of dirt into the valve. Very robust design The overall design of the AVK valve meets and exceeds all standards for gas applications and ensures a long functional life cycle in most harsh environments. Extension spindle and tee keys The connector is designed to adapt to all extension spindles and tee keys according to european standards. The yellow coloured bearing ring also seals off the ball spindle below to avoid ingress of water. It also acts as an indicator to show the valve open and closed position. Series Features and Benefits

10 10 SERIES Features and benefits A B A B Seat retainer The seat retainer design ensures the ball seat is kept in place at all times. This optimal design prevents the ball seat from being dislodged, which guarantees a good functionality throughout the years. Spindle shaft The groove around the spindle shaft allows the internal pressure to equalise the compression on the O-ring over the complete circumference. At the same time the groove will adapt to any deformation as a result of upstream pressure on the ball when the valve is in the closed position. Series Features and Benefits

11 SERIES valve options and ACCESSORIES 11 Standard valve range Range: 32mm to 180mm Valve with fully welded fixed length extension spindle Range: 63mm to 180mm Valve with fully welded fixed length extension spindle and single 50mm pressure point Range: 63mm to 180mm Valve with fully welded fixed length extension spindle and double 50mm pressure points Range: 63mm to 180mm The AVK PE Ball valve range is now available with purge and bypass points to enable them to be used for the safe isolation of pipe sections between strategic valves. The purge and bypass points are fully welded and pressure rated the same as the main valve. A bypass can be connected to the outer bypass point to enable gas to remain flowing even when the valve itself is closed. Once the bypass has been established and the gas is flowing the two strategic valves can be closed without interruption of the gas flow to the end user. When the strategic valves are closed the section of pipe between them is effectively isolated. The next stage in the process is to purge the gas from the isolated section. This is done by connecting a purge stack to the two inner purge points. Once the purge stacks are connected the inner purge points can be opened allowing the residual gas in the isolated section to be purged out. Thereby making the section of pipe safe to work on. Once work on the isolated section is complete the purge valves can be closed, the strategic valves can be opened and the bypass removed without any interruption to the mains gas flow. Series ACCESSORIES As with all valves, best practice techniques should be used during installation and operation. To aid this process a series of recommended accessories are available, these include a bespoke installation and access system, extension spindle and operating tee keys. Telescopic retro fit extension spindle Tee key (50mm Square) Installation kits/valve access system Series Options and Accessories

12 12 SERIES REFERENCE NUMBERS Description Reference Number MOP Specification Standard Valves DN 32mm SDR 11 Valve bar EN , DVGW VP302 DN 40mm SDR 11 Valve bar EN , DVGW VP302 DN 50mm SDR 11 Valve bar EN , DVGW VP302 DN 63mm SDR 11 Valve bar EN , DVGW VP302 DN 75mm SDR 11 Valve bar EN , DVGW VP302 DN 90mm SDR 11 Valve bar EN , DVGW VP302 DN 110mm SDR 11 Valve bar EN , DVGW VP302 DN 125mm SDR 11 Valve bar EN , DVGW VP302 DN 160mm SDR 11 Valve bar EN , DVGW VP302 DN 180mm SDR 11 Valve bar EN , DVGW VP302 Valves with Fully Welded Stem Extension DN 63mm SDR 11 Valve bar EN , DVGW VP302 DN 90mm SDR 11 Valve bar EN , DVGW VP302 DN 110mm SDR 11 Valve bar EN , DVGW VP302 DN 125mm SDR 11 Valve bar EN , DVGW VP302 DN 160mm SDR 11 Valve bar EN , DVGW VP302 DN 180mm SDR 11 Valve bar EN , DVGW VP302 Valves with Fully Welded Stem Extension and 1 Pressure Point DN 63mm SDR 11 Valve bar EN , DVGW VP302 DN 90mm SDR 11 Valve bar EN , DVGW VP302 DN 110mm SDR 11 Valve bar EN , DVGW VP302 DN 125mm SDR 11 Valve bar EN , DVGW VP302 DN 160mm SDR 11 Valve bar EN , DVGW VP302 DN 180mm SDR 11 Valve bar EN , DVGW VP302 Valves with Fully Welded Stem Extension and 2 Pressure Points DN 63mm SDR 11 Valve bar EN , DVGW VP302 DN 90mm SDR 11 Valve bar EN , DVGW VP302 DN 110mm SDR 11 Valve bar EN , DVGW VP302 DN 125mm SDR 11 Valve bar EN , DVGW VP302 DN 160mm SDR 11 Valve bar EN , DVGW VP302 DN 180mm SDR 11 Valve bar EN , DVGW VP302 Installation Kits Details Install Kits for 32/180mm Valves N/A Complete with Surface Box Install Kits for 32/180mm Valves N/A Excludes Surface Box Tee Keys Details Operating Tee Key 0.75m Long N/A 50mm Square Drive Operating Tee Key 1.0m Long N/A 50mm Square Drive Operating Tee Key 1.5m Long N/A 50mm Square Drive Extension Spindles Details Telescopic Extension Spindle TBA N/A , , , , Fixed Length Extension Spindle TBA N/A 699 to 804 depending on valve size Series Reference Numbers

13 AVK Certus pe valves for water applications 13 Although this brochure is dedicated to valves for gas, AVK also has a full range of PE ball valves which are specifically designed and manufactured for water applications and as such are certified to ISO Details of the valves are available on data sheets and in the water valves brochure. For more details on all our products, services and distributor partners visit our website AVK Certus PE Valves for water application

14 14 Other gas valves & fittings available from avk uk Series 555 Donkin Cast Iron DN , PN7 Cast Iron G15/V7 Part 1 Series 555 D Donkin Ductile Iron DN , PN7/10 Ductile Iron G15/V7 Part 1 Series 555 S Flanged Donkin Steel DN , PN7/19 Cast Steel G15/V7 Part 1 Series 555 PE Donkin Cast Iron/PE DN90-315, PN 4/7 Cast Iron GIS V7 Part 1 GIS PL3 Series 555D PE Donkin Ductile Iron/PE DN90-315, PN 7 Ductile Iron GIS V7 Part 1 GIS PL3 Series 555 S Donkin Steel DN50-300, PN19/50 Cast Steel GIS/V7 Part 1 Series 555 Donkin Large Diameter DN , PN2 Cast Iron GIS/V7 Part 1 Series 555 D Donkin Large Diameter DN , PN4/7 Ductile Iron GIS/V7 Part 1 Series 555 S Donkin Large Diameter DN , PN7 Cast Steel GIS/V7 Part 1 Series 158 Donkin Under Pressure Drilling Valve DN80-300, PN7 Cast Iron GIS/V7 Part1 Series 777 Donkin Slide Valve DN , PN2 Fabricated Steel EN Series 594 & 595 Donkin Non-Return Valve DN , PN7 Cast Iron Ductile Iron or Fabricated Steel EN Series 450 Donkin Ball Valve DN40-150, PN7 Ductile Iron Body Stainless Steel Ball GIS/V7 Part 1 BS5159, EN Series 451 Donkin Service Isolation Valve DN3/4-2 /25-63 PN4/7 Ducitile Iron Body Stainless Steel GIS/V4, GIS/PL3 Series 455 & 455LD Donkin Ball Valve DN 3/4 /1 /2, PN 7 Ductile Iron GIS/V4, GISE1 GIS/PL3 Other Gas Valves & Fittings Available From AVK UK

15 Other gas valves & fittings available from avk uk 15 Series 460/02 Donkin Steel Ball Valve DN20-50, PN7 Carbon Steel Body Stainless Steel Ball BS 5150 Series 310/061 Donkin Flow Limitor DN32, Range HDPE GIS / EFV1 Series 310/080 Integral Flow Limitor Approved to MSS SP (Fits into Electrofusion Coupler or Reducer) Range 0.69bar - 7 bar Series 310/25 25mm Integral Flow Limitor Approved to BGE/S/V/5 and MSS SP-115 (Fits into Service Pipe) Range 500mbar bar Series 310/32 32mm High Capacity Integral Flow Limitor Approved to BGE/S/V/5 and MSS SP-115 (Fits into Service pipe) Range 500mbar - 4 bar Series 310/063 Donkin Flow Limitor Approved to MSS SP-115 DN32 Range 0.69bar - 7bar Series 203/31 Donkin Pipe Saver Repair Clamp DN15-60, PN2 Stainless Steel GIS/LC8 Part 4 Series 257/31 Donkin Universal Tee DN Ductile Iron GIS/LC8 Part 8 Series 253/31 Donkin Supacollar Universal Repair Clamp DN80-300, PN7 Ductile Iron GIS/LCS Part 4 Series 207/31 Donkin Live Transfer Fitting DN1-2, PN2/7 Stainless Steel GIS/LC8 Part 4 Series 202/31 Donkin Multiple Band Repair Clamp DN , PN2/7 Stainless Steel GIS/LC8 Part 4 Series 248/32 Donkin Universal End Cap DN80-300, PN2 Ductile Iron GIS/F13 Series 213/31 Donkin Fabricated Hot-Tap Weld-on Tee DN50-600mm, PN7 Mild Steel Series 214/31 Donkin Fabricated Flowstop Tee DN mm, PN7 Mild Steel Series 215/31 Donkin Stainless Steel Tee DN , PN2/7 Stainless Steel GIS/LC8 Part4 Other Gas Valves & Fittings Available From AVK UK

16 Northampton Office 8 Rushmills, Northampton, NN4 7YB England, UK. Tel: +44 (0) Fax: +44 (0) Chesterfield Office enquiries@avkuk.co.uk 24/7 Emergency Same Day Repair Clamp Service For Gas & Water CER-0312 Copyright AVK Group A/S 2012 Colliery Close, Ireland Ind.Est., Staveley, Chesterfield, S43 3FH, England, UK. Tel: +44 (0) Fax: +44 (0)

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