VSI AWWA C508 Series Installation and operating instructions

VSI Waterworks
2” - 48” AWWA C508
RUBBER FLAPPER CHECK VALVE
Publicaon: 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 instrucons are for the AWWA C508 Rubber Flapper Check Valves and who will be
responsible for the installaon, operaon and maintenance of the valves.
SAFETY MESSAGES:
All Safety messages in this manual are agged with an exclamaon symbol and the word
Danger, Cauon or Warning. These messages indicate procedures that must be followed
exactly to avoid equipment damage, personal injury or death.
WARNING!
Personnel involved in the installaon or maintenance of valves should be constantly alert to
potenal emissions of pipeline material and take appropriate safety precauons. Always wear
suitable protecon when dealing with hazardous pipeline material, also handle valves that
have been removed from service with suitable protecon from any potenal pipeline material
in the valve.
INSPECTION:
Your AWWA C508 Rubber Flapper Check Valve has been packaged to provide protecon during
shipping. However, it is sll 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 Soluons Inc. sales representave. Please include the serial
number, located on the valve tag, when ordering parts.
WARNING!
Read all applicable instrucons and direcons prior to any maintenance, installaon or
troubleshoong.

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 signicant component part of many reghng or water-distribuon
systems. Failure of a Rubber Flapper Swing Check Valve in such systems, either caused by faulty installaon or
improper maintenance, could result in extensive damage and costly repairs. Problems with or malfuncons of
the Valves caused by faulty installaon or improper maintenance can result in extensive and costly unearthing
operaons to eecvely correct or eliminate the problem. Many Rubber Flapper Swing Check Valves problems
and failures can be traced back to improper handling, storage, installaon, operaon, 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 protecve coang. Each valve should be carefully lowered from the truck to the ground; it
should not be dropped. Valves should not be lied 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, forklis 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 recommendaons 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
inial inspecon should verify compliance with specicaons, direcon of opening, size, and operator(s). A
visual inspecon of the seang surfaces should be performed to detect any damage in shipment or scoring
of the seang surfaces. Inspecon 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 posion in which it is to be installed.
SECTION 4 - STORAGE
Whenever praccal, 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 essenal to prevent water from collecng in the valves. Failure to do so
may result in a cracked valve casng or deterioraon of the disc material.
SECTION 5 - INSTALLATION
Instrucons supplied by manufacturers should be reviewed in detail before valves are installed. At the jobsite
prior to installaon, each valve should be visually inspected and any foreign material in the interior poron of
the valve should be removed. A detailed inspecon of the valve as outlined in Sec. 3 should be performed prior
to installaon.
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 protecon.

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-distribuon lines shall, where praccal, be located in easily accessible areas.
5.2.1 During installaon, there is the possibility of foreign materials inadvertently entering the valve.
Foreign material can damage internal working parts during operaon of the Check Valves. For this reason,
Check Valves should be installed in the closed posion with the embossed ow arrow on the valve body
poinng in the direcon of ow. Each valve should be placed on rm foong in the trench to prevent seling
and excessive strain on the connecon to the pipe. Piping systems should be supported and aligned to avoid
damage to the valve.
Sec. 5.3 Inspection
Aer installaon and before pressurizaon of the valve, all pressure-containing bolng (top cover plate, seals,
and end connecons) should be inspected for adequate ghtness to prevent leakage. In addion, an inspecon
should be made for adequate ghtness of all tapped and plugged openings to the valve interior. Proper
inspecon at this me will minimize the possibility of leaks aer pressurizaon of the piping system.
Sec. 5.4 Hydrostatic testing
To prevent me lost searching for leaks, it is recommended that valve excavaons not be backlled unl aer
pressure tests have been made. Aer installaon, it is desirable to hydrostacally test newly installed piping
secons, including Valves, at some pressure above the system design pressure. The test pressure should not
exceed the rated working pressure of the Valve. Aer 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 direcon at dierenal pressures above the rated working pressure. It should be noted that
Valves seat beer at or near the rated working pressure of the valve. It is also recognized that wear or foreign
material may damage valve seang surfaces and may cause leakage (Ref. AWWA C600).
Sec. 5.5 Records
Upon compleon of the installaon, valve locaon, size, make, type, date of installaon, number of turns to
open, direcon of opening, and other informaon deemed pernent should be entered on permanent records.
Sec. 5.6 Application Hazards
Rubber Flapper Swing Check Valves should not be installed in applicaons or for service other than those rec-
ommended by the manufacturer. The following subsecons for precauons are not all inclusive but will help
avoid some applicaon 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 applicaons 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 condions 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 posion on a me schedule
designed to prevent a buildup of tuberculaon or other deposits that could render the Valve. The interval of
me between operaons of Valves in crical locaons, or Valves subjected to severe operang condions,
should be shorter than that for less important installaons, but can be whatever me period is found to
be sasfactory based on local experience. Maintenance should be performed at the me a malfuncon is
discovered. A recording system should be adopted that provides a wrien record of valve locaon, condion,
maintenance, and each subsequent inspecon 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 applicaons 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 aachment opon causes the disc to accelerate valve closure. Having the Valve
closed before reverse ow occurs can in many instances drascally reduce or even eliminate Valve slam.
Sec. 6.3 Inspection
Each valve should be operated through one complete operang cycle. With the Check Valve in the parally
open posion, a visual inspecon should be performed, where praccal, to check for leakage at all joints,
connecons, and areas of seals. If leakage is observed, all defecve O-rings, seals, gaskets, or end connecon
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 locaon should be clearly established to save me for repair crews. The condion of the
valve and, if possible, the posion, should be reported to personnel responsible for repairs. In addion, 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 roune maintenance, but should be included as part of
the normal facility equipment inspecons for any malfuncon while under normal usage condions.
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. Aer 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 adjusng 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 inspecon and maintenance program, it is essenal that the locaon, make, type,
size, and date of installaon of each valve be recorded. Depending on the type of record-keeping system used,
other informaon 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 indicang the date of inspecon and condion of
the valve. If repair work is necessary, it should be indicated, and on compleon of the work, the nature of the
repairs and date completed should be recorded.
SECTION 7: REPAIRS
Leakage, broken parts, hard operaon, and other major defects should be corrected by a repair crew as soon
as possible aer 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 defecve
valve from water pressure and relieve internal trapped pressure prior to performing any correcve mainte-
nance. Disassembly of the valve should be performed in accordance with the procedure supplied by the manu-
facturer. Aer repair of the valve, the operang mechanism should be cycled through one complete operang
cycle. With full line pressure applied to the valve in the open posion, an inspecon should be made to detect
leakage in the areas around the cover, seals, and body-end connecons. A record should be made to indicate
that the valve has been repaired and is in working condion. Any markings indicang that the valve is inoper-
able should be removed. In addion, the appropriate municipal departments should be informed of the sas-
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 Correcon
The valve will not seal
Interference between valve disc
and seang surface
Follow instrucons for
disassembly(maintenance secon) and
check for any interference
Uneven ghtening of the cover or
accessories
Loosen then reghten bolts and nuts
evenly
Corrosion or debris in accessories
Follow instrucons for
disassembly(maintenance secon) and
clean accessories
Debris under disc
Follow instrucons for
disassembly(maintenance secon) and
clean out debris
Leakage between the
body and cover of the
valve
Bolts and nuts may be loose or
ghtened irregularly
Loosen then reghten bolts and nuts
evenly
Cover Gasket may be damaged
Follow instrucons for
disassembly(maintenance secon) and
replace gasket
RARE: Crack in body or cover Inspect and replace if necessary
Leakage at accessories Damaged operator Replace accessory in its enrety
Damaged o-rings
Valve fails pressure test
Valve is not completely closed Close valve completely
Debris trapped under disc
Throle valve from fully closed to
approximately 25% open several
mes under line ow to clear debris.
If unsuccessful follow instrucons for
disassembly and remove debris
Disc encapsulaon or seat is
damaged
Follow disassembly instrucons 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 backush aachment 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 deformaon.
5. Clean all seang and mang 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 paern
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 backush aachment fully inward by rotang in a clockwise direcon to equalize pressure across
valve.
3. Loosen and remove the enre backush aachment at its hex base.
4. Inspect for bends, nicks, or other damage. Replace if damaged.
5. Replace backush aachment using new seal and teon thread sealant
6. Screw backush aachment fully outward by rotang in a counterclockwise direcon
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 backush aachment 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 teon thread sealant
7. Return valve to service and check for leaks.