BB 1... BB 2... Installation and Maintenance Instructions 810677-01 Dual-Plate Check Valves BB 1..., BB 2... 1
Contents Important Notes Page 2 Usage for the intended purpose... 8 Safety note... 8 Warning... 8 Ratings pursuant to article 9 of the PED... 9 Explanatory Notes Scope of supply... 10 Description... 10 Function... 10 Technical data... 11 12 Corrosion resistance... 12 Sizing... 12 Name plate / marking... 13 Installation Springs... 14 BB 1..., BB 2...... 14 BB 1... with dampers, BB 2... with dampers... 14 Installation note... 15 Commissioning BB 1..., BB 2...... 16 Operation BB 1..., BB 2...... 16 Maintenance BB 1... : Changing springs and O rings... 17 18 Tools... 18 BB 2... : Changing springs... 19 21 Tools... 21 Torques... 22 24 Spare Parts Spare parts list... 25, 26 Annex Declaration of Conformity... 27
Component Parts BB 1... A A B C D J J G G H I E I F A H Fig. 1 3
Component Parts BB 2... K D B C L H J J I F H G I G L Fig. 2 K 4
Component Parts BB 1... with dampers J B A A C D J E G H I I H G E F A M Fig. 3 5
Key A B C D E F G H I J K L M Sealing plug with gasket Eyebolt Name plate Body Plate support O-ring Semi-circular valve plates Spring Spring Hinge pin Hinge pin support Threaded bolt Damper (cpl.) with gasket 6
Pressure Drop Chart Fig. 4 7
Important Notes Usage for the intended purpose The swing and dual-plate check valves BB ensure unidirectional flow in pipes by preventing a backflow of liquids or gases. Use this equipment only within the specified pressure and temperature ratings and check corrosion resistance and chemical suitability for the application in question. Safety note The valve must only be installed by qualified staff. Qualified staff are those persons who through adequate training in engineerng, the use and application of safety equipment in accordance with regulations concerning safety systems, and first aid & accident prevention have achieved a recognised level of competence appropriate to the installation and commissioning of this device. Danger The valve is under pressure during operation. When loosening flanged connections or sealing plugs, hot water, steam, corrosive liquids or toxic gases may escape. This presents the danger of severe burns and scalds to the whole body or severe cases of poisoning. Installation and maintenance work should only be carried out when the system is depressurized. The valve becomes hot or extremely cold during operation. This presents the risk of severe burns to hands and arms. Installation and maintenance work should only be carried out at room temperatures. Sharp edges on internals present a danger of cuts to hands. Always wear industrial gloves for installation and maintenance work. 8
Important Notes continued Ratings pursuant to article 9 of the PED 1 ) Fluid group Gas Liquid 1 2 1 2 Use BB 12/21 G, PN 6 to no yes no yes BB 14/24 G, PN 16 BB 12/22 A, C, PN 10 to yes yes yes yes BB 19 A, C, PN 160 BB 12/22 M, PN 10 to yes yes yes yes BB 16/26 M, PN 40 Category Exception pursuant to article 3.3 I II III IV Nominal size [mm] DN DN DN DN DN BB 11/21 G, PN 6 150 200 500 600 800 BB 11/22 G, PN 10 150 350 400 500 600 800 BB 14/24 G, PN 16 150 200 250 300 350 800 BB 12/22 A, C, PN 10 100 125 350 400 800 BB 14/24 A, C, PN 16 100 200 250 800 BB 15/25 A, C, PN 25 100 125 150 800 BB 16/26 A, C, PN 40 100 125 800 BB 17 A, C, PN 63 100 125 500 BB 18 A, C, PN 100 100 125 500 BB 19 A, C, PN 160 150 300 BB 12/22 M, PN 10 150 350 400 600 BB 14/24 M, PN 16 150 200 250 600 BB 15/25 M, PN 25 150 600 BB 16/26 M, PN 40 150 600 CE marking no yes yes yes no 1 ) PED = Pressure Equipment Directive 9
Explanatory Notes Scope of supply BB 1... 1 Dual-plate check valve type BB 1... 1 Installation manual BB 2... 1 Dual-plate check valve type BB 2... 1 Installation manual BB 1... D 1 Dual-plate check valve type BB 1... with dampers 1 Installation manual BB 2... D 1 Dual-plate check valve type BB 2... with dampers 1 Installation manual Description Swing and dual-plate check valves BB feature two separately suspended semicircular plates pivoting on an independent hinge pin. The two plates open and close automatically allowing fluid to flow in one direction only. The opening pressure and closing time can be customized by modifying the spring characteristic. Hydraulic dampers are also available as optional extras to solve waterhammer problems. Installation in any position, with due regard to our installation recommendations. Our dual-plate check valves are fitted with eyebolts for easy installation and transit protection. Please note that dual-plate check valves should not be used on reciprocating compressors, piston pumps or where pulsating flow exists. Function The low opening pressure of the dual-plate check valves is a function of the spring characteristics. When the opening pressure is reached the hinge sides of the plates open first, thereby eliminating any possibility of the seats scuffing. As the pressure and flowrate rise, the opening angle increases symmetrically. Media entering the valve at an unfavourable angle (e. g. due to pipe bends) may cause an asymmetrical opening of the plates. If centrifugal pumps are installed upstream of the valve it becomes necessary to arrange for a defined stabilizing section. Systems where pulsating flow exists require specially designed dual-plate check valves. Make sure to install valves which are not fitted with springs in a vertical position with downward flow. Please note the installation recommendations outlined in the following pages. 10
Explanatory Notes continued Technical Data Pressure/temperature ratings*) for BB, grey cast iron down to 10 C at nominal pressure p-t series to EN 1092-2, table 17, quality class 250, DN 150-800 mm Temperature [ C] 20 100 150 200 250 300 350 400 450 500 550 PN BB 11 G, BB 21 G [bar] 6 6 5.4 4.8 4.2 3.6 6 BB 12 G, BB 22 G [bar] 10 10 9.0 8.0 7.0 6.0 10 BB 14 G, BB 24 G [bar] 16 16 14.4 12.8 11.2 9.6 16 *) When used for its intended purpose. Pressure/temperature ratings*) for BB, carbon steel down to 10 C at nominal pressure p-t series to EN 1092-1, table 15, material group 4E0, DN 150-800 mm Temperature [ C] 20 100 150 200 250 300 350 400 450 500 550 PN BB 12 C, BB 22 C [bar] 10 10 10 9.6 8.9 7.6 7.1 6.7 6.4 10 BB 14 C, BB 24 C [bar] 16 16 16 15.3 14.2 12.1 11.4 10.7 10.3 16 BB 15 C, BB 25 C [bar] 25 25 25 23.9 22.2 18.9 17.8 16.7 16.1 25 BB 16 C, BB 26 C [bar] 40 40 40 38.2 35.6 30.2 28.4 26.7 25.8 40 *) When used for its intended purpose. If t > 300 C spring 7 WAI required. Pressure/temperature ratings*) for BB, carbon steel down to 10 C at nominal pressure p-t series to EN 1092-2, table 17, material group 3E0, DN 150-500 mm (BB 19C, DN 150-300 mm) Temperature [ C] 20 100 150 200 250 300 350 400 450 500 550 PN BB 17 C [bar] 63 58.5 54.6 47.6 44.8 40.6 37.8 36.4 63 BB 18 C [bar] 100 93.3 86.7 75.6 71.1 64.4 60.0 57.8 100 BB 19 C [bar] 160 149.3 138.7 121.0 113.8 103.0 96.0 92.5 160 *) When used for its intended purpose. If t > 300 C spring 7 WAI required. Pressure/temperature ratings*) for BB, molybdenum-free stainless steel down to 200 C at nominal pressure p-t series to EN 1092-1, table 18, material group 12E0, DN 150-600 mm Temperature [ C] 20 100 150 200 250 300 350 400 450 500 550 PN BB 12 M, BB 22 M [bar] 10 9.3 8.7 8.2 7.8 7.4 7.2 6.9 6.8 6.6 6.3 10 BB 14 M, BB 24 M [bar] 16 14.9 13.9 13.2 12.4 11.9 11.4 11.1 10.8 10.6 10.1 16 BB 15 M, BB 25 M [bar] 25 23.3 21.7 20.6 19.4 18.6 17.9 17.3 16.9 16.6 15.8 25 BB 16 M, BB 26 M [bar] 40 37.3 34.7 32.9 31.1 29.7 28.6 27.7 27.0 26.5 25.2 40 *) When used for its intended purpose. If t > 300 C spring 7 WAI required. 11
Explanatory Notes continued Technical Data continued Pressure/temperature ratings*) for BB, stainless steel down to 105 C at nominal pressure p-t series to EN 1092-1, table 18, material group 12E0, DN 150-800 mm (BB 19 A, DN 150-300 mm) Temperature [ C] 20 100 150 200 250 300 350 400 450 500 550 PN BB 12 A, BB 22 A [bar] 10 9.3 8.7 8.2 7.8 7.4 7.2 6.9 6.8 6.6 6.3 10 BB 14 A, BB 24 A [bar] 16 14.9 13.9 13.2 12.4 11.9 11.4 11.1 10.8 10.6 10.1 16 BB 15 A, BB 25 A [bar] 25 23.3 21.7 20.6 19.4 18.6 17.9 17.3 16.9 16.6 15.8 25 BB 16 A, BB 26 A [bar] 40 37.3 34.7 32.9 31.1 29.7 28.6 27.7 27.0 26.5 25.2 40 BB 17 A [bar] 63 58.8 54.6 51.8 49.0 46.8 45.1 43.7 42.6 41.7 39.8 63 BB 18 A [bar] 100 93.3 86.7 82.2 77.8 74.2 71.6 69.3 67.6 66.2 63.0 100 BB 19 A [bar] 160 149.3 138.7 131.5 124.5 118.7 114.6 110.9 108.2 105.9 101.0 160 *) When used for its intended purpose. If t > 300 C spring 7 WAI required. Pressure/temperature ratings*) for BB, grey cast iron, cast steel down to 10 C at nominal pressure Dual-plate check valve BB with LEVASINT or hard rubber lining Temperature [ C] 10 LEVASINT Hard rubber max. 70 max. 90 PN BB 11 G, BB 21 G [bar] 6 6 6 6 BB 12 G, BB 22 G [bar] 10 10 10 10 BB 14 G, BB 24 G [bar] 16 16 16 16 BB 12 C, BB 22 C [bar] 10 10 10 10 BB 14 C, BB 24 C [bar] 16 16 16 16 *) When used for its intended purpose. Corrosion Resistance When used for its intended purpose the safe functioning of the steam trap will not be impaired by corrosion. Sizing The valve body must not be subjected to sharp increases in pressure. Welds and flanges of the valve are designed to withstand dynamic loading (bending and alternative stress). The dimensional allowances for corrosion reflect the latest state of technology. 12 LEVASINT is a registered trademark of Bayer AG, Leverkusen.
Explanatory Notes continued Name Plate / Marking Type code BB 1... as specified by EN ISO 26552 Direction of flow For further ratings to EN 19 see valve body. 2 indicates the manufacturing year 2002. 2002 Fig. 5 Type code BB 2... as specified by EN ISO 26552 Direction of flow For further ratings to EN 19 see valve body. 2 indicates the manufacturing year 2002. 2002 Fig. 6 13
Installation 14 Springs The dual-plate check valve BB 1..., BB 2... with standard springs may be fitted in horizontal pipework or in vertical pipework with upward flow. For downward flow special springs are required. For more information refer to our data sheet Dual- Plate Check Valve BB. Spring 7 WA Spring for 7 mbar opening pressure, suitable for horizontal installation or vertical installation with upward flow. Spring 2 WA Spring for 2 mbar opening pressure, suitable for horizontal installation or vertical installation with upward flow. Spring 5 VO Spring for 5 mbar opening pressure, suitable for horizontal installation or vertical installation with downward flow. Note BB 1..., BB 2... Depending on the volume flow, the dual-plate check valve opens either completely or only partly. During partial opening, i. e. at a reduced volume flow (cf. pressure drop chart instable range), clatter may occur which gives rise to wear on the valve seat and plates, Fig. 4. Installing a dual-plate check valve with spring type 5 VO in horizontal lines or vertical lines with upward flow may result in loud noises, scuffing and subsequent wear on the seat. 1. Please note our installation recommendations on page 15. 2. Clean plate seats. 3. Horizontal flow: Insert flange bolts through bottom flange bore and tighten nuts. Use off-the-shelf seals. 4. Mount and align dual-plate check valve BB, making sure that the eyebolt B is on top. Insert and tighten flange bolts. 5. Vertical flow: Insert commerical grade seals (bottom). 6. Mount and align dual-plate check valve BB. Insert off-the-shelf seals (top). Insert and tighten flange bolts. BB 1... with dampers, BB 2... with dampers 1. Please note our installation recommendations on page 15. 2. Use only the eyebolt B as aid for installaing the valve. Do not attach steel or nylon slings to damping cylinder M. 3. Do not tread on damping cylinder M. 4. Proceed as described under BB 1..., BB 2....
Installation continued incorrect correct Fig. 7 Fig. 8 optimum with pump Fig. 9 Fig. 10 15
Commissioning BB 1..., BB 2... Dual-plate check valves BB... do not require special preparations prior to their commissioning. If the springs or O-rings of the dual-plate check valves BB 1... have been replaced check plugs A for positive sealing and, if necessary, retighten them. Please refer to pages 22 to 24 for information on torques. If the dual-plate check valves BB... have not been properly positioned in the pipework or are fitted with unsuitable springs the consequent vibrations and clattering of the plates will give rise to loud noises. In this case either increase the capacity of the pump or replace the springs by suitable ones. Please observe the installlation notes. Do not attach objects to or tread on the damping cylinders M of the dual-plate check valves BB with dampers. Operation BB 1..., BB 2... If the dual-plate check valves BB... have not been properly positioned in the pipework or are fitted with unsuitable springs the consequent vibrations and clattering of the plates will give rise to loud noises. In this case either increase the capacity of the pump or replace the springs by suitable ones. Please observe the installlation notes. Do not attach objects to or tread on the damping cylinders M of the dual-plate check valves BB with dampers. 16
Maintenance GESTRA dual-plate check valves BB... do not require any special maintenance. However, in certain cases (cf. Commissioning ) it might be necessary to replace the springs or O-rings. Danger Note that springs are preloaded, which means that they can jump out of the plate body when the valve is being installed or removed. This presents the risk of injuries to hands, arms and face. Replacing springs /O-rings of the BB 1... 1 2 Dual-plate check valve BB 1... 3 Undo screws, remove springs and withdraw hinge pins. 4 Take out springs, semicircular plates, support plates and, if fitted, O-rings. Insert new springs with tension plates and hinge pins. 17
Maintenance continued Replacing springs / O-rings of the BB 1... continued 5 6 Screw in and tighten screws. Remove tension plates. 7 Install dual-plate check valve BB 1... Tools Spanner socket A. F. 17, 19, 22, 24 mm to DIN 3124 Hexagon socket spanner A. F. 5, 6, 10, 12 mm to ISO 2936 Torque spanner 10-60 Nm, 60-120 Nm, DIN ISO 6789 18
Maintenance continued Danger Note that springs are preloaded, which means that they can jump out of the plate body when the valve is being installed or removed. This presents the risk of injuries to hands, arms and face. Replacing springs of the BB 2... 1 2 Dual-plate check valve BB 2... Undo threaded bolts, turn semicircular plates to the left. 3 4 Take out semicircular plates, springs and support plates. Remove support plates, cover springs and withdraw hinge pins. 19
Maintenance continued Replacing springs of the BB 2... continued 5 6 Insert new springs using tension plates. Fit hinge pins and support plates. Align support plates. 7 8 Remove tension plates. Insert semicircular plates with springs and support plates. 20
Maintenance continued Replacing springs of the BB 2... continued 9 10 Align semicircular plates. Insert and tighten threaded bolts. Mount dual-plate check valve BB 2... Tools Spanner socket A. F. 17, 19, 22, 24 mm to DIN 3124 Hinged face spanner A. F. 2-8 mm (for valves with polymer/hard rubber lining) Torque spanner 10-60 Nm, 60-120 Nm, DIN ISO 6789 21
Maintenance continued Torques [Nm] Item DN [mm] Austenitic steel BB 11... BB 12... BB 14... BB 15... BB 16... BB 17... BB 18... BB 19... 100 13 13 13 13 13 13 125 13 13 13 13 27 27 150 65 65 65 200 135 135 135 250 135 135 135 300 135 135 320 A 350 260 260 400 320 320 450 310 310 310 310 310 500 310 310 310 310 310 630 630 600 310 310 310 310 310 630 630 700 1080 1080 1080 1080 1080 800 2240 2240 2240 2240 2240 900 1940 1940 1940 1940 1940 1000 1940 1940 1940 1940 1940 1200 45 45 45 45 45 Do not use lubricant for fastening bolts. Austenitic steel Item DN [mm] BB 21... BB 22... BB 24... BB 25... BB 26... 150 15 15 15 15 15 200 15 15 15 15 15 L 250 26 26 26 26 26 300 26 26 26 26 26 350 26 26 26 26 26 400 70 70 70 70 70 Do not use lubricant for fastening bolts. 22
Maintenance continued Torques [Nm] Item DN [mm] Bronze BB 11... BB 12... BB 14... BB 15... BB 16... BB 17... BB 18... BB 19... 100 125 150 27 27 27 200 58 58 58 250 58 58 58 300 58 58 230 A 350 110 110 400 230 230 450 310 310 310 310 310 500 310 310 310 310 310 460 460 600 310 310 310 310 310 460 460 700 460 460 460 460 460 800 940 940 940 940 940 900 1420 1420 1420 1420 1420 1000 1420 1420 1420 1420 1420 1200 19 19 19 19 19 Do not use lubricant for fastening bolts. Bronze Item DN [mm] BB 21... BB 22... BB 24... BB 25... BB 26... 150 17 17 17 17 17 200 17 17 17 17 17 L 250 28 28 28 28 28 300 28 28 28 28 28 350 28 28 28 28 28 400 78 78 78 78 78 Do not use lubricant for fastening bolts. 23
Maintenance continued Torques [Nm] Item DN [mm] Austenitic steel/body D covered with hard rubber lining or LEVASINT BB 21... BB 22... BB 24... BB 25... BB 26... 150 7.5 7.5 7.5 7.5 7.5 200 7.5 7.5 7.5 7.5 7.5 L 250 15 15 15 15 15 300 15 15 15 15 15 350 26 26 26 26 26 400 42 42 42 42 42 Do not use lubricant for fastening bolts. Item L DN [mm] Bronze/Body D covered with hard rubber lining or LEVASINT BB 21... BB 22... BB 24... BB 25... BB 26... 150 8 8 8 8 8 200 8 8 8 8 8 250 17 17 17 17 17 300 17 17 17 17 17 350 28 28 28 28 28 400 47 47 47 47 47 Do not use lubricant for fastening bolts. 24 LEVASINT is a registered trademark of Bayer AG, Leverkusen.
Spare Parts Spare Parts List Item DN Stock code EPDM Stock code FPM Stock code NBR Stock code PTFE 100 037847 038982 038543 125 346777 346778 346779 150 342598 342711 342931 342978 200 342710 342713 344372 343721 250 342522 342523 344484 344491 300 182574 038718 340825 344592 F 350 400 342565 342584 342569 342585 038705 344714 175131 344715 450 038948 180962 037020 500 036002 036007 182719 343876 600 036003 180210 122490 700 036987 343603 182114 750 344939 342120 183105 800 039663 181939 Minimum purchasing quantity 20 pcs. Two O-rings are required per valve. Contact your local dealer for small quantities. 25
Spare Parts continued Spare Parts List Item DN Stock code 2 WA Stock code 7 WA Stock code 5 VO Stock code 7 WAI 100 348200 348190 348198 348220 125 348201 348191 348199 348221 150 248202 348192 348209 348222 200 348203 348193 348211 348223 250 348204 348194 348213 348224 H 300 348205 348195 348215 348225 I 350 348206 348196 348216 348226 400 348207 348197 348217 348227 450 348586 348580 348598 on request 500 348587 348581 348600 on request 600 348588 348582 on request 700 348589 348583 on request 750 348584 on request 800 348591 348585 on request Springs complete with tension plates. Contact your local dealer for small quantities. 26
Annex Declaration of Conformity We hereby declare that the pressure equipment BB 1... and BB 2... conform to the following European Directive: EC Pressure Equipment Directive (PED) No. 97/23 of 29 May 1997 Dual-plate check valves are pressure equipment as defined in article 1, section 2.1.4 of the PED. Applied conformity assessment procedure for valves up to DN 300 mm: Module A1 as described in Annex III. Applied conformity assessment procedure for valves larger than DN 300 mm: Module H as described in Annex III and verified by the Notified Body 0525. This declaration is no longer valid if modifications are made to the equipment without consultation with us. Bremen, 16 th July 2001 GESTRA GmbH Head of the Design Dept. Uwe Bledschun Academically qualified engineer Quality Assurance Representative Lars Bohl 27
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