Block 12 Pipeline Ancillaries Check Valves Module 12.

3
SC-GCM-96 CM Issue 2 © Copyright 2007 Spirax-Sarco Limited

Module 12.3
Check Valves

The Steam and Condensate Loop 12.3.1

Block 12 Pipeline Ancillaries Check Valves Module 12.3

Check Valves
Check valves, or non-return valves, are installed in pipeline systems to allow flow in one direction
only. They are operated entirely by reaction to the line fluid and therefore do not require any
external actuation. In this text, the expected, or desired direction of flow is termed ‘forward flow’,
flow in the opposite direction is ‘reverse flow’.
There are a number of reasons for using check valves, which include:
o Protection of any item of equipment that can be affected by reverse flow, such as flowmeters,
strainers and control valves.
o To check the pressure surges associated with hydraulic forces, for example, waterhammer.
These hydraulic forces can cause a wave of pressure to run up and down pipework until the
energy is dissipated.
o Prevention of flooding.
o Prevention of reverse flow on system shutdown.
o Prevention of flow under gravity.
o Relief of vacuum conditions.
Although check valves can effectively shut off reverse flow, they should never be used in
place of an isolation valve to contain live steam, in a section of pipe.
As with isolation valves, there are a number of different check valve designs, each suited to
specific applications. The different types of check valve and their applications are discussed in
this module, along with the correct sizing method.

Lift check valves

Lift check valves are similar in configuration to globe valves, except that the disc or plug is
automatically operated. The inlet and outlet ports are separated by a cone shaped plug that rests
on a seat typically metal; in some valves, the plug may be held on its seat using a spring. When
the flow into the valve is in the forward direction, the pressure of the fluid lifts the cone off its
seat, opening the valve. With reverse flow, the cone returns to its seat and is held in place by the
reverse flow pressure.

Forward
flow

Fig. 12.3.1 A lift check valve

12.3.2 The Steam and Condensate Loop

Block 12 Pipeline Ancillaries Check Valves Module 12.3

If a metal seat is used, the lift check valve is only suitable for applications where a small amount
of leakage, under reverse flow conditions, is acceptable. Furthermore, the design of a lift check
valve generally limits its use to water applications, subsequently, they are commonly used to
prevent reverse flow of condensate in steam traps and on the outlets of cyclic condensate pumps.
The main advantage of the lift check valve lies in its simplicity, and as the cone is the only moving
part, the valve is robust and requires little maintenance. In addition, the use of a metal seat limits
the amount of seat wear. The lift check valve has two major limitations; firstly, it is designed only
for installation in horizontal pipelines, and secondly, its size is typically limited to DN80, above
which, the valve would become too bulky.
The piston-type lift check valve is a modification of the standard lift check valve. It incorporates
a piston shaped plug instead of the cone, and a dashpot is applied to this mechanism. The
dashpot produces a damping effect during operation, thereby eliminating the damage caused by
the frequent operation of the valve, for example, in pipeline systems, which are subject to surges
in pressure, or frequent changes in flow direction (one example would be a boiler outlet).

Swing check valves

A swing check valve consists of a flap or disc of the same diameter as the pipe bore, which hangs
down in the flow path. With flow in the forwards direction, the pressure of the fluid forces the
disc to hinge upwards, allowing flow through the valve. Reverse flow will cause the disc to shut
against the seat and stop the fluid going back down the pipe. In the absence of flow, the weight
of the flap is responsible for the closure of the valve; however, in some cases, closure may be
assisted by the use of a weighted lever. As can be seen from Figure 12.3.2, the whole mechanism
is enclosed within a body, which allows the flap to retract out of the flow path.

Cover
Hinge pin

Disc

Forward flow

Seat ring

Body

Fig. 12.3.2 A full-bodied, swing check valve

Swing check valves produce relatively high resistance to flow in the open position, due to the
weight of the disc. In addition, they create turbulence, because the flap ‘floats’ on the fluid
stream. This means that there is typically a larger pressure drop across a swing check valve than
across other types.
With abrupt changes in flow, the disc can slam against the valve seat, which can cause significant
wear of the seat, and generate waterhammer along the pipe system. This can be overcome by
fitting a damping mechanism to the disc and by using metal seats to limit the amount of seat
wear.

Wafer check valves

Both lift and swing check valves tend to be bulky which limits their size and makes them costly.
To overcome this, wafer check valves have been developed. By definition wafer check valves are
those that are designed to fit between a set of flanges. This broad definition covers a variety of
different designs, including disc check valves and wafer versions of swing or split disc check
valves.

The Steam and Condensate Loop 12.3.3

Block 12 Pipeline Ancillaries Check Valves Module 12.3

Disc check valves

The disc check valve consists of four main components: the body, a disc, a spring and a spring
retainer. The disc moves in a plane at right angles to the flow of the fluid, resisted by the spring
that is held in place by the retainer. The body is designed to act as an integral centring collar that
facilitates installation. Where a ‘zero leakage’ seal is required, a soft seat can be included.

Forward flow

Spring retainer

Spring
Disc

Body

Fig. 12.3.3 A disc check valve

When the force exerted on the disc by the upstream pressure is greater than the force exerted by
the spring, the weight of the disc and any downstream pressure, the disc is forced to lift off its
seat, allowing flow through the valve. When the differential pressure across the valve is reduced,
the spring forces the disc back onto its seat, closing the valve just before reverse flow occurs. This
is shown in Figure 12.3.4. The presence of the spring enables the disc check vale to be installed
in any direction.
Disc
Seat Spring

Forward Reverse
flow flow

Open Closed
Fig. 12.3.4 Operation of a disc check valve

The differential pressure required to open the check valve is mainly determined by the type of
spring used. In addition to the standard spring, there are several spring options available:
o No spring - Used where the differential pressure across the valve is small.
o Nimonic spring - Used in high temperature applications.
o Heavy-duty spring - This increases the required opening pressure. When installed in the boiler

feedwater line, it can be used to prevent steam boilers from flooding when they are unpressurised.
As with all wafer check valves, the size of the disc check valve is determined by the size of the
associated pipework. This usually ensures that the valve is correctly sized, but there are cases
where the valve is over or undersized.

12.3.4 The Steam and Condensate Loop

Block 12 Pipeline Ancillaries Check Valves Module 12.3

An oversized check valve is often indicated by continuous valve chatter, which is the repeated
opening and closing of the valve that occurs when the valve is only partially open. It is caused by
the fact that when the valve opens, there is a drop in the upstream pressure; if this pressure drop
means that the differential pressure across the valve falls below the required opening pressure,
the valve will slam shut. As soon as the valve shuts, the pressure begins to build up again, and so
the valve opens and the cycle is repeated.
Oversizing can usually be rectified by selecting a smaller valve, but it should be noted that this
will increase the pressure drop across the valve for any one flow. If this is not acceptable, it may
be possible to overcome the effects of chatter by reducing the closing force on the disc. This can
be done either by using a standard spring instead of a heavy-duty one, or by removing the spring
altogether. Another alternative is to use a soft seat; this does not prevent the chatter but rather,
reduces the noise. Care must be taken however, as this may cause excessive wear on the seat.
Undersizing results in excessive pressure drop across the valve and, in the extreme, it may even
prevent flow. The solution is to replace the undersized valve with a larger one.
Disc check valves are smaller and lighter than lift and standard swing check valves and subsequently
cost less. The size of a disc check valve is however limited to DN125; above this, the design
becomes complicated. Typically, such a design would include a cone shaped disc and a small
diameter spring that is retained and guided along the centre line of the cone, which is more
difficult and expensive to manufacture. Even then, such designs are still limited in size to DN250.
Standard disc check valves should not be used on applications where there is heavily pulsating
flow, for example, on the outlet of a reciprocating air compressor, as the repeated impact of the
disc can lead to failure of the spring retainer and high levels of stress in the spring. Specifically
designed retainers are available for such applications. These designs typically reduce the amount
of disc travel, which effectively increases the resistance to flow and therefore increases the pressure
drop across the valve.
The design of disc check valves allows them to be installed in any position, including vertical
pipelines where the fluid flows downwards.

Swing type wafer check valves

These are similar to the standard swing check
valves, but do not have the full-bodied
arrangement, instead, when the valve opens, the
flap is forced into the top of the pipeline.
Subsequently, the flap must have a smaller
diameter than that of the pipeline, and because
of this, the pressure drop across the valve, which Forward
is often high for swing type valves, is further flow
increased.
Swing type check valves are used mainly on larger
pipeline sizes, typically above DN125, because
on smaller pipelines the pressure drop, caused
by the disc ‘floating’ on the fluid stream, becomes
significant. Furthermore, there are significant cost
savings to be made by using these valves on larger
sizes, due to the small amount of material
required for the construction of the valve. Fig. 12.3.5 Swing type wafer check valve

There is however one problem with using larger size valves; due to their size, the discs are
particularly heavy, and therefore possess a large amount of kinetic energy when they close. This
energy is transferred to the seat and process fluid when the valve slams shut, which could cause
damage to the seat of the valve and generate waterhammer.

The Steam and Condensate Loop 12.3.5

Block 12 Pipeline Ancillaries Check Valves Module 12.3

Wafer check valve applications

Wafer check valves are becoming the preferred type of check valve for most applications, due to
their compact design and relatively low cost. The following is a list of some of their most common
applications:
o Boiler feedlines - The check valve is used to prevent boiler water being forced back along the
feedline into the storage tank when the feedpump stops running. Furthermore, a disc check
valve with a heavy-duty spring and a soft seat can be fitted in the boiler feedline to prevent
flow under gravity into the boiler when the feedpump is shut off.

Fig. 12.3.6 Boiler feedline applications

o Steam traps - Other than with steam traps discharging to atmosphere, check valves should
always be inserted after a steam trap to prevent back flow of condensate flooding the steam
space. The check valve will also prevent the steam trap from becoming damaged by any
hydraulic shock in the condensate line. It should be noted that when using blast discharge
type steam traps, the check valve should be fitted at least 1 m downstream of the trap.

Fig. 12.3.7 Steam trap applications

12.3.6 The Steam and Condensate Loop

Block 12 Pipeline Ancillaries Check Valves Module 12.3

o Hot water circuits - A check valve should be installed after each pump to prevent reverse flow
through the pump when it has been shut off (see Figure 12.3.8).

Water

DCV

Fig. 12.3.8 Duplex pump set

o Vacuum breakers - Check valves can be used as vacuum breakers, by fitting them in reverse.
When a vacuum is created, the valve opens, allowing air to be drawn in from the atmosphere
(see Figure 12.3.9).

Steam
Disc check valve fitted as a vacuum breaker

Tank
Injector

Fig. 12.3.9 Steam injection into a tank

o Blending - A check valve should be fitted in each supply line to prevent reverse flow along the
different lines which will lead to contamination. A common blending application is the mixing
of hot and cold water to provide hot water (see Figure 12.3.10).

Cold water supply

Check valve

Mixing valve Blended water

Check valve

Hot water supply

Fig. 12.3.10 Blending applications

The Steam and Condensate Loop 12.3.7

Block 12 Pipeline Ancillaries Check Valves Module 12.3

o Pipeline fitting protection - Check valves are used to prevent damage to equipment such as
flowmeters and control valves, all of which can be damaged by reverse flow. Check valves also
stop the contents of strainers from being deposited in upstream pipework by back flowing
fluid.
o Multiple boiler applications - A check valve must be inserted on the outlet of each boiler
to prevent any steam flowing into boilers, which may be on hot stand-by (see Figure 12.3.11).

On line On line On stand-by

Fig. 12.3.11 Multiple boiler applications

o Blowdown vessels - When a blowdown vessel receives blowdown from more than one boiler,
a wafer check valve should be installed on each separate blowdown line. This will prevent the
blowdown from one boiler flowing back into another boiler. In many countries, this is a statutory
requirement.
o Flash vessels - A wafer check valve is installed at the flash steam outlet from the flash vessel;
this ensures that steam from any make-up valve does not flow back into the flash vessel (see
Figure 12.3.12). A check valve is also installed after the steam trap that drains the flash vessel.

Steam

Check valve

Condensate and steam

Condensate
Fig. 12.3.12 Flash vessel applications

12.3.8 The Steam and Condensate Loop

Block 12 Pipeline Ancillaries Check Valves Module 12.3

Split disc check valves

The split disc check valve or dual plate check valve is designed to overcome the size and pressure
drop limitations of the swing and disc type wafer check valves. The flap of the swing check valve
is essentially split and hinged down its centre, such that the two disc plates will only swing in one
direction. The disc plates are held against the seat by a torsion spring mounted on the hinge.
In order to hold the hinge in the centre of the flow path, externally mounted retainer pins can be
used. These retainer pins are a common source of leakage from the valve. An improved design
secures the hinge internally, and as the valve mechanism is entirely sealed within the body,
leakage to atmosphere is prevented (see Figure 12.3.13).

Fig. 12.3.13 A split disc check valve (retainerless design)

The valve is normally closed, as the disc plates are kept shut by the torsion spring. When fluid
flows in the forwards direction, the pressure of the fluid causes the disc plates to hinge open,
allowing flow. The check valve is closed by the spring as soon as flow ceases, before any reverse
flow can occur.

Forward Reverse
flow flow

Open Closed
Fig. 12.3.14 Operation of a split disc check valve

The frequent opening and closing of the split disc check valve would soon cause seat damage if
the heels of the disc plates were allowed to scuff against the seat during opening. To overcome
this, the heel of the disc plates lift during the initial opening of the valve and the plates rotate
purely on the hinge as opposed to the seat face.
The split disc type of check valve has several advantages over other types of check valves:
o The split disc design is not limited in size and these valves have been produced in sizes of up
to DN5400.
o The pressure drop across the split disc check valve is significantly lower than across other
types.
o They are capable of being used with lower opening pressures.
o Split disc check vales can be installed in any position, including vertical pipelines.

The Steam and Condensate Loop 12.3.9

Block 12 Pipeline Ancillaries Check Valves Module 12.3

Other check valve types

The above mentioned types of check valve are the most commonly encountered types in steam,
condensate, and liquid systems. However, several other types are also available. The three types
listed below are mainly suited to liquid applications and subsequently may be found in condensate
systems:
o Ball check valve - This consists of a rubber-coated ball that is normally seated on the inlet
to the valve, sealing off the inlet. When pressure is exerted on the ball, it is moved off its
seat along a guide rail, allowing fluid to pass through the inlet. When the fluid pressure drops,
the ball slides back into its position on the inlet seat. Note: Ball check valves are typically only
used in liquid systems, as it is difficult to obtain a tight seal using a ball.
o Diaphragm check valve - A flexible rubber diaphragm is placed in a mesh or perforated
cone with the point in the direction of flow in the pipeline (see Figure 12.3.15). Flow in the
forwards direction deflects the diaphragm inwards, allowing the free passage of the fluid.
When there is no flow or a backpressure exists, the diaphragm returns to its original position,
closing the valve. Note: The diaphragm material typically limits the application of the
diaphragm check valve to fluids below 180°C and 16 bar.

Forward flow Reverse flow

Open Closed

Fig. 12.3.15 A diaphragm check valve

o Tilting disc check valve - This is similar to the swing type check valve, but with the flap
pivoted in front of its centre of pressure and counterweighted or spring loaded to assume a
normally closed position (see Figure 12.3.16). When flow is in the forwards direction, the disc
lifts and ‘floats’ in the stream offering minimum resistance to flow. The disc is balanced so that
as flow decreases, it will pivot towards its closed position, closing before reverse flow actually
commences. The operation is smooth and silent under most conditions. Note: due to the
design of the tilting disc check valve, it is limited to use on liquid applications only.

Full forward flow Low flow Reverse flow

Open Closed Closed

Fig. 12.3.16 Operation of a tilting disc check valve

12.3.10 The Steam and Condensate Loop

Block 12 Pipeline Ancillaries Check Valves Module 12.3

Pressure loss charts

As most types of check valve are suitable for use on both liquid and gas systems, manufacturers
typically show the pressure drop across a valve in the form of a pressure loss chart for water. A
typical pressure loss chart is shown in Figure 12.3.17. It shows the pressure drop across a particular
check valve for a given valve size and water flowrate in m3/h.
200 50

100 30
70 20
50 100
DN
Water flowrate (Vw) m3/h

Water flowrate (Vw) I/s

80 10
30 DN 5
20 D 60
N
5 5
DN
N 40 3
10 D
2
7 DN3 2
5 25
DN 1
3 0
DN2
2 5
DN1 0.5
1 0.3
0.7 0.2
0.5
0.01 0.02 0.05 0.1 0.2 0.5 1
Pressure loss in bar
Fig. 12.3.17 A typical manufacturer’s pressure loss diagram

In order to determine the pressure drop across the check valve for other liquids, the equivalent
water volume flowrate needs to be calculated, this is done using the formula in Equation 12.3.1:

ρ
Z    Equation 12.3.1

Where:
Vw = Equivalent water volume flowrate (m³ / h)
r = Density of the liquid (kg / m³)
V = Volume flowrate of liquid (m³ / h)
Once the equivalent water volume flowrate has been determined, the pressure drop across the
valve can be read off the chart using the same method as for water, selecting the equivalent water
volume flowrate instead of the actual volume flowrate.
It should be noted that the volumetric flowrate (in m3 / h) is typically quoted for liquid applications,
whereas, in steam applications, the mass flowrate (in kg / h) is normally used. To convert from
kg / h to m3/h, the mass flowrate is multiplied by the specific volume (in kg / m3) for the particular
working pressure and temperature (see Equation 12.3.2).

 = QJ Equation 12.3.2

Where:
V = Volume flowrate (m³ / h)
m = Mass flowrate (kg / h)
ng = Specific volume (m³ / kg)

The Steam and Condensate Loop 12.3.11

Block 12 Pipeline Ancillaries Check Valves Module 12.3

Alternatively, if the Kv value of the valve is specified, the pressure drop across the valve can be
determined using the method outlined in Module 12.2.

Example 12.3.1
Determine the pressure drop across a DN65 check valve passing 1 200 kg / h of saturated steam
at 8 bar g. Use the pressure drop characteristics shown in Figure 12.3.17.
Solution:
The first step is to calculate the volumetric flowrate:
From steam tables at 8 bar gauge, ng = 0.214 9 m³ / kg
Using Equation 12.3.2
V = [ QJ
V = 1 200 kg / h x 0.214 9 m³ / kg
V = 257 m³ / h

The next step is to calculate the equivalent water volume flowrate:

Using Equation 12.3.1:
ρ
Z  
Since n = 0.214 9 m³ / kg, the density, r =

 = 4.65 kg / m³
  Pó K
Z  
Vw = 17.6 m³ / h

Using Figure 12.3.18, the pressure drop across the valve would be approximately 0.085 bar.

200 50

100 30
70 20
50 100
DN
Water flowrate (Vw) m3/h

10
Water flowrate (Vw) I/s

80
30 DN 5
20 DN60
5 5
17.6 m³/h DN
40
10 DN 3
2
7 DN3 2
5 25
DN 1
3 0
DN2
2 5
DN1 0.5
1 0.3
0.7 0.2
0.5
0.01 0.02 0.05 0.1 0.2 0.5 1
0.085 bar
Pressure loss in bar

Fig. 12.3.18

12.3.12 The Steam and Condensate Loop

Block 12 Pipeline Ancillaries Check Valves Module 12.3

Questions

1. Which of the following is not a suitable application of a check valve?

a| To prevent waterhammer ¨
b| To isolate a heat exchanger for upstream maintenance ¨
c| To prevent damage to a flowmeter ¨
d| To divert flow in a blending operation ¨

2. Which of the following can be used to prevent the problems associated with
swing check valves, namely waterhammer and seat wear?
a| Limit the velocity of the fluid, by increasing the pipe diameter ¨
b| Replace the metal seat with a soft (PTFE) seat ¨
c| Fit a damping mechanism to the flap ¨
d| Fit a wafer swing check valve ¨

3. A thermodynamic steam trap is used to drain a steam main.

How far downstream of the trap should a check valve be fitted?
a| Less than 1 m ¨
b| At least 1 m ¨
c| As close to the outlet as possible ¨
d| It is not necessary to fit a check valve in this situation ¨

4. What advantage does a split disc check valve have over other types of
wafer check valves?
a| It is not limited in size ¨
b| The pressure drop across the valve is lower ¨
c| It can be used with lower opening pressures ¨
d| All of the above ¨

5. Which of the following may be used to eliminate the effects of valve chatter
caused by oversizing a disc check valve?
a| Use a spring with a lower spring force ¨
b| Use a soft seat ¨
c| Replace the oversized valve with a smaller valve ¨
d| All of the above ¨

6. A disc check valve with the pressure loss diagram shown in Figure 12.3.17 is used
downstream of a control valve. The downstream pipeline has a diameter of 32 mm,
and passes 200 kg / h of saturated steam at 5 bar g.
Determine the pressure drop across the check valve?
a| 0.05 bar ¨
b| 0.25 bar ¨
c| 1.55 bar ¨
d| 5.00 bar ¨

Answers
1: b, 2: c, 3: b, 4: d, 5: d, 6: a

The Steam and Condensate Loop 12.3.13

Block 12 Pipeline Ancillaries Check Valves Module 12.3

12.3.14 The Steam and Condensate Loop