VSI AWWA C508 Series Installation and operating instructions

VSI Waterworks
2” - 48” AWWA C508
RUBBER FLAPPER CHECK VALVE
Publicaon: VRSG-3
FEB 2016
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
VSI AWWA C508 RUBBER FLAPPER CHECK VALVE

INSTALLATION, OPERATION AND MAINTENANCE
VSI AWWA C508 RUBBER FLAPPER CHECK VALVE
VRSG-3
02-16 © 2014 VSI Waterworks LLC
2
TABLE OF CONTENTS
INSTRUCTIONS 3
SAFETY MESSAGES 3
GENERAL 4
UNLOADING 4
INSPECTION PRIOR TO INSTALLATION 4
STORAGE 4
INSTALLATION 4
INSPECTION AND MAINTENANCE 6
TROUBLESHOOTING 8
DISASSEMBLY AND REASSEMBLY 9

INSTALLATION, OPERATION AND MAINTENANCE
VSI AWWA C508 RUBBER FLAPPER CHECK VALVE
© 2014 VSI Waterworks LLC VRSG-3
02-16
3
INSTRUCTIONS:
These instrucons are for the AWWA C508 Rubber Flapper Check Valves and who will be
responsible for the installaon, operaon and maintenance of the valves.
SAFETY MESSAGES:
All Safety messages in this manual are agged with an exclamaon symbol and the word
Danger, Cauon or Warning. These messages indicate procedures that must be followed
exactly to avoid equipment damage, personal injury or death.
WARNING!
Personnel involved in the installaon or maintenance of valves should be constantly alert to
potenal emissions of pipeline material and take appropriate safety precauons. Always wear
suitable protecon when dealing with hazardous pipeline material, also handle valves that
have been removed from service with suitable protecon from any potenal pipeline material
in the valve.
INSPECTION:
Your AWWA C508 Rubber Flapper Check Valve has been packaged to provide protecon during
shipping. However, it is sll possible to be damaged during shipping. Please inspect the unit for
damage upon arrival and le a claim if damage is apparent.
PARTS:
Order parts from your Valve Soluons Inc. sales representave. Please include the serial
number, located on the valve tag, when ordering parts.
WARNING!
Read all applicable instrucons and direcons prior to any maintenance, installaon or
troubleshoong.

INSTALLATION, OPERATION AND MAINTENANCE
VSI AWWA C508 RUBBER FLAPPER CHECK VALVE
VRSG-3
02-16 © 2014 VSI Waterworks LLC
4
SECTION 1 - GENERAL
Rubber Flapper check valves form a signicant component part of many reghng or water-distribuon
systems. Failure of a Rubber Flapper Swing Check Valve in such systems, either caused by faulty installaon or
improper maintenance, could result in extensive damage and costly repairs. Problems with or malfuncons of
the Valves caused by faulty installaon or improper maintenance can result in extensive and costly unearthing
operaons to eecvely correct or eliminate the problem. Many Rubber Flapper Swing Check Valves problems
and failures can be traced back to improper handling, storage, installaon, operaon, or maintenance
procedures.
SECTION 2 - UNLOADING
All valves should be unloaded carefully; a so sling around the body is recommended to prevent damage to
the valve and its protecve coang. Each valve should be carefully lowered from the truck to the ground; it
should not be dropped. Valves should not be lied or unloaded using chains, slings, or forkli fork(s) engaging
the valve accessories or passing through the valve waterway. In the case of larger valves, forklis or slings
around the body of the valve or under the skids should be used for unloading. Only hoists and slings with
adequate load capacity to handle the weight of the valve or valves should be used. Hoists should not be should
not be hooked through the seat opening in the body. Failure to carefully follow these recommendaons is
likely to result in damage to the valve.
SECTION 3 - INSPECTION PRIOR TO INSTALLATION
Rubber Flapper Swing Check Valves should be inspected at the me of receipt for damage in shipment. The
inial inspecon should verify compliance with specicaons, direcon of opening, size, and operator(s). A
visual inspecon of the seang surfaces should be performed to detect any damage in shipment or scoring
of the seang surfaces. Inspecon personnel should look for bent rod(s), cracked parts, loose bolts, missing
parts and accessories, and any other evidence of mishandling during shipment. Each valve should be operated
through one complete opening-and-closing cycle in the posion in which it is to be installed.
SECTION 4 - STORAGE
Whenever praccal, valves should be stored indoors. If outside storage is required, valves should be protected
from the weather, sunlight, ozone, and foreign materials. In colder climates where valves may be subject to
freezing temperatures, it is absolutely essenal to prevent water from collecng in the valves. Failure to do so
may result in a cracked valve casng or deterioraon of the disc material.
SECTION 5 - INSTALLATION
Instrucons supplied by manufacturers should be reviewed in detail before valves are installed. At the jobsite
prior to installaon, each valve should be visually inspected and any foreign material in the interior poron of
the valve should be removed. A detailed inspecon of the valve as outlined in Sec. 3 should be performed prior
to installaon.
Sec. 5.1 Bolts
All bolts should be checked for proper ghtness and protected by the installer to prevent corrosion, either with
a suitable paint, by polyethylene wrapping, or other suitable means of corrosion protecon.

INSTALLATION, OPERATION AND MAINTENANCE
VSI AWWA C508 RUBBER FLAPPER CHECK VALVE
© 2014 VSI Waterworks LLC VRSG-3
02-16
5
Sec. 5.2 Installation
Valves in water-distribuon lines shall, where praccal, be located in easily accessible areas.
5.2.1 During installaon, there is the possibility of foreign materials inadvertently entering the valve.
Foreign material can damage internal working parts during operaon of the Check Valves. For this reason,
Check Valves should be installed in the closed posion with the embossed ow arrow on the valve body
poinng in the direcon of ow. Each valve should be placed on rm foong in the trench to prevent seling
and excessive strain on the connecon to the pipe. Piping systems should be supported and aligned to avoid
damage to the valve.
Sec. 5.3 Inspection
Aer installaon and before pressurizaon of the valve, all pressure-containing bolng (top cover plate, seals,
and end connecons) should be inspected for adequate ghtness to prevent leakage. In addion, an inspecon
should be made for adequate ghtness of all tapped and plugged openings to the valve interior. Proper
inspecon at this me will minimize the possibility of leaks aer pressurizaon of the piping system.
Sec. 5.4 Hydrostatic testing
To prevent me lost searching for leaks, it is recommended that valve excavaons not be backlled unl aer
pressure tests have been made. Aer installaon, it is desirable to hydrostacally test newly installed piping
secons, including Valves, at some pressure above the system design pressure. The test pressure should not
exceed the rated working pressure of the Valve. Aer the test, steps should be taken to relieve any trapped
pressure in the body of the valve. The Rubber Flapper Swing Check Valve should not be operated in either the
opening or closing direcon at dierenal pressures above the rated working pressure. It should be noted that
Valves seat beer at or near the rated working pressure of the valve. It is also recognized that wear or foreign
material may damage valve seang surfaces and may cause leakage (Ref. AWWA C600).
Sec. 5.5 Records
Upon compleon of the installaon, valve locaon, size, make, type, date of installaon, number of turns to
open, direcon of opening, and other informaon deemed pernent should be entered on permanent records.
Sec. 5.6 Application Hazards
Rubber Flapper Swing Check Valves should not be installed in applicaons or for service other than those rec-
ommended by the manufacturer. The following subsecons for precauons are not all inclusive but will help
avoid some applicaon hazards.
a. Rubber Flapper Swing Check Valves should not be installed in lines where service pressure will exceed
the rated working pressure of the valve.
b. Rubber Flapper Swing Check Valves should not be used in applicaons that are exposed to freezing
temperatures.
c. Thrust blocks, restrained joints, or other means of restraint are needed on or adjacent to valves on
pipelines or where unusual condions exist, such as high internal pressures, adjacent ngs, or
unstable soils.

INSTALLATION, OPERATION AND MAINTENANCE
VSI AWWA C508 RUBBER FLAPPER CHECK VALVE
VRSG-3
02-16 © 2014 VSI Waterworks LLC
6
SECTION 6: INSPECTION AND MAINTENANCE
Sec. 6.1 Valve Exercising
Each Valve should be operated through a full cycle and returned to its normal posion on a me schedule
designed to prevent a buildup of tuberculaon or other deposits that could render the Valve. The interval of
me between operaons of Valves in crical locaons, or Valves subjected to severe operang condions,
should be shorter than that for less important installaons, but can be whatever me period is found to
be sasfactory based on local experience. Maintenance should be performed at the me a malfuncon is
discovered. A recording system should be adopted that provides a wrien record of valve locaon, condion,
maintenance, and each subsequent inspecon of the valve
Sec. 6.2 Spring Return Attachment Option
Rubber Flapper Swing Check Valves is designed to minimize or eliminate slam in high head applicaons where
rapid ow reversal causes the Swing Check Valve to slam. The Valve has a 35° disc stroke, leaving 80° to 90° of
travel. Having the spring return aachment opon causes the disc to accelerate valve closure. Having the Valve
closed before reverse ow occurs can in many instances drascally reduce or even eliminate Valve slam.
Sec. 6.3 Inspection
Each valve should be operated through one complete operang cycle. With the Check Valve in the parally
open posion, a visual inspecon should be performed, where praccal, to check for leakage at all joints,
connecons, and areas of seals. If leakage is observed, all defecve O-rings, seals, gaskets, or end connecon
sealing members should be replaced. If the leakage cannot be corrected immediately, the nature of the
leakage should be reported promptly to those who are responsible for repairs. If the valve is inoperable
or irreparable, its locaon should be clearly established to save me for repair crews. The condion of the
valve and, if possible, the posion, should be reported to personnel responsible for repairs. In addion, the
appropriate municipal departments should be informed that the valve is out of service.
Sec. 6.4 Maintenance
ATTENTION: DO NOT WORK ON ANY VALVE UNDER PRESSURE
Rubber Flapper Swing Check Valves does not require roune maintenance, but should be included as part of
the normal facility equipment inspecons for any malfuncon while under normal usage condions.
a. Relieve the pressure in the line.
b. Isolate the Rubber Flapper Swing Check Valve from the system before loosening the cover bolts
to remove the cover.
c. Loosen each cover bolt only three to four full turns, tapping the side of the cover with a rubber
mallet to separate only Valve cover from the cover gasket. By doing so, this will relieve any
pressure in the Valve.
d. Loosen to remove all cover bolts and li the cover. Aer removing the cover of the valve, the
Flapper will be fully exposed and freely removed. The Flapper, the cover gasket, and the body
surfaces of the Check Valve should be fully examined for wear. If replacement parts are needed,
contact the manufacture with Valve type, size, and the appropriate parts.
e. Reassemble, replace the cover gasket.
f. Replace Flapper and be sure that the Flapper rests at and centered against the body seat
surfaces.

INSTALLATION, OPERATION AND MAINTENANCE
VSI AWWA C508 RUBBER FLAPPER CHECK VALVE
© 2014 VSI Waterworks LLC VRSG-3
02-16
7
Sec. 6.5 Maintenance - Spring Return
The spring adjusng mechanism where all components are made of stainless steel and a Rubber Flapper
encapsulates a reinforcing plate. The Rubber Flapper Swing Check Valve requires no maintenance.
Sec. 6.6 Record Keeping
To carry out a meaningful inspecon and maintenance program, it is essenal that the locaon, make, type,
size, and date of installaon of each valve be recorded. Depending on the type of record-keeping system used,
other informaon may be entered in the permanent record. When a Rubber Flapper Swing Check Valve is
inspected, an entry should be made in the permanent record indicang the date of inspecon and condion of
the valve. If repair work is necessary, it should be indicated, and on compleon of the work, the nature of the
repairs and date completed should be recorded.
SECTION 7: REPAIRS
Leakage, broken parts, hard operaon, and other major defects should be corrected by a repair crew as soon
as possible aer the defect has been reported. If repairs are to be performed in the eld, the repair crews
should take a full complement of spare parts to the jobsite. Provisions should be made to isolate the defecve
valve from water pressure and relieve internal trapped pressure prior to performing any correcve mainte-
nance. Disassembly of the valve should be performed in accordance with the procedure supplied by the manu-
facturer. Aer repair of the valve, the operang mechanism should be cycled through one complete operang
cycle. With full line pressure applied to the valve in the open posion, an inspecon should be made to detect
leakage in the areas around the cover, seals, and body-end connecons. A record should be made to indicate
that the valve has been repaired and is in working condion. Any markings indicang that the valve is inoper-
able should be removed. In addion, the appropriate municipal departments should be informed of the sas-
factory repair of the valve.

INSTALLATION, OPERATION AND MAINTENANCE
VSI AWWA C508 RUBBER FLAPPER CHECK VALVE
VRSG-3
02-16 © 2014 VSI Waterworks LLC
8
SECTION 8: TROUBLESHOOTING
Problem Cause Correcon
The valve will not seal
Interference between valve disc
and seang surface
Follow instrucons for
disassembly(maintenance secon) and
check for any interference
Uneven ghtening of the cover or
accessories
Loosen then reghten bolts and nuts
evenly
Corrosion or debris in accessories
Follow instrucons for
disassembly(maintenance secon) and
clean accessories
Debris under disc
Follow instrucons for
disassembly(maintenance secon) and
clean out debris
Leakage between the
body and cover of the
valve
Bolts and nuts may be loose or
ghtened irregularly
Loosen then reghten bolts and nuts
evenly
Cover Gasket may be damaged
Follow instrucons for
disassembly(maintenance secon) and
replace gasket
RARE: Crack in body or cover Inspect and replace if necessary
Leakage at accessories Damaged operator Replace accessory in its enrety
Damaged o-rings
Valve fails pressure test
Valve is not completely closed Close valve completely
Debris trapped under disc
Throle valve from fully closed to
approximately 25% open several
mes under line ow to clear debris.
If unsuccessful follow instrucons for
disassembly and remove debris
Disc encapsulaon or seat is
damaged
Follow disassembly instrucons and inspect
for damage. If present replace damaged
parts.

INSTALLATION, OPERATION AND MAINTENANCE
VSI AWWA C508 RUBBER FLAPPER CHECK VALVE
© 2014 VSI Waterworks LLC VRSG-3
02-16
9
SECTION 9: DISASSEMBLY AND REASSEMBLY
ATTENTION: DO NOT WORK ON ANY VALVE UNDER PRESSURE
Sec. 9.1 Basic Valve Disassembly and Reassembly
1. Shut o line ow fully and equalize pressure across valve by backush aachment or other means
2. Remove bonnet cover bolts and washers
3. Remove disc from valve body
4. Inspect and replace disc if it is damaged. There should be no cracks or deformaon.
5. Clean all seang and mang surfaces before beginning reassembly
6. Replace disc into valve body
7. Replace bonnet cover using new seal
8. Reinstall cover bolts and washers
9. Tighten to 90 lbs using a cris-cross paern
10. Return valve to service and check for leaks
Sec. 9.2 Backflush Attachment Disassembly and Reassembly
1. Shut o line ow fully.
2. Screw backush aachment fully inward by rotang in a clockwise direcon to equalize pressure across
valve.
3. Loosen and remove the enre backush aachment at its hex base.
4. Inspect for bends, nicks, or other damage. Replace if damaged.
5. Replace backush aachment using new seal and teon thread sealant
6. Screw backush aachment fully outward by rotang in a counterclockwise direcon
7. Return valve to service and check for leaks
Sec. 9.3 Indicator Atachment Disassembly and Reassembly
1. Shut o line ow fully.
2. Equalize pressure across valve by backush aachment or other means
3. Remove packing seal nut from cover of valve by loosening hex counterclockwise
4. Inspect and replace o-rings if necessary
5. Li indicator sha and disc and polish with extra ne 800 grit or higher sand paper to remove nicks or
damage
6. Reinstall packing seal nut using new seal and teon thread sealant
7. Return valve to service and check for leaks.
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