Document No.

: KE-0030-01

Operation Manual
For
KITZ Wafer Type Check Valves
125 FWNB

We appreciate your purchasing our products.

Read all the contents of this manual before piping and using them. Also keep
this manual in a place accessible to the operator.
Document No. : KE-0030-01

This manual applies to the manual operation of the KITZ wafer type check valves.

CAUTION AND WARNING

To ensure safe and trouble-free function and performance, please read all the contents of
this manual before handling, transportation, mounting and operation of the products.
Keep this manual in a place accessible to the operator.

The signs “WARNING” and “CAUTION” are defined as follows:

Indicates potentially hazardous conditions, which may result in

serious injury to personnel, if such warnings are ignored.

Indicates potentially hazardous conditions, which may result in

minor or moderate injury to personnel or property damage, if
such cautions are ignored.

Indicates a “prohibited” action that must not be carried out.

Indicates a “mandatory” action that must be followed.

NOTES TO USERS
This manual covers normal usage of the products. Technical data and instructions for operation,
maintenance and inspection of the products are prepared in consideration of safety. However,
they are good only to cover typical applications as a general guideline to the users. If technical
assistance beyond this manual is required, contact KITZ Corporation or its distributors.

The illustrations given in this manual do not introduce all the details. If more detailed data are
needed, refer to our relevant valve assembly drawings.

*Any information provided in this manual is subject to change at any time without notice.
Document No. : KE-0030-01

Contents

I. Construction and Design Features ･････････････････････････ 1

II. Transportation and Storage ････････････････････････････････ 6

III. Valve Installation ･････････････････････････････････････････ 9

IV. Valve Operation ･･･････････････････････････････････････ 14

V. Periodic Inspection ････････････････････････････････････････ 18

VI. Disassembly and Assembly ･･･････････････････････････････ 22

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I. Construction and Design Features

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I. Construction and Design Features

1. Construction and function

1.1 Construction and parts names are as indicated in the figure below.

1.2 The disc is turned with a pivot of the hinge pin by the force of velocity pressure and
closed by the force of helical spring and gravity.

1.3 Only unidirectional flow is applied to prevent reverse flow.

1.4 The flow direction of the valve is indicated on the valve body.

1.5 It is recommended to have a distance of 6 times or over the nominal size from the outlet
of the pump, reducer and elbow to prevent swirling, turbulence or pulsation.

This illustration shows typical construction.

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I. Construction and Design Features

2. Design feature

2.1 Reduction of water hammer

The valve is able to reduce water hammer because the spring assisted disc will close
immediately before the flow reversal.

2.2 Compact and light mass

Its compact size is helpful in installations where clearances are minimal.

2.3 Low pressure-loss

The slim configuration allows for minimal pressure loss.
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I. Construction and Design Features

3. Valve specifications

3.1 Maximum working pressure and temperature

3.2 Test pressure

Shell Test Seat Test Low-pressure Seat Test

(Hydraulic or air) (Hydraulic or air) (Hydraulic or air)
1.5MPa 1.5MPa 0.05MPa
( 217 lb/in2 ) ( 217 lb/in2 ) ( 7.3 lb/in2 )
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I. Construction and Design Features

4. Dimensions and required quantities of piping bolts

Bolt dimensions and the required quantities of piping bolts are as shown in the table
below. The bolts lengths shown in the table are calculated based on the use of a steel
flange and a gasket with 3 mm thickness.

Type A Type B
Valve Bolt
nominal size nominal size L S Quantity L Quantity

2 5/8 4.3 1.50 4 5.1 4

21/2 5/8 4.5 1.50 4 5.1 4
3 5/8 4.7 1.50 4 5.5 4
4 5/8 5.3 1.50 8 6.1 8
5 3/4 5.7 1.75 8 6.5 8
6 3/4 6.1 2.00 8 6.9 8
8 3/4 7.1 2.00 8 7.9 8
10 7/8 7.9 2.25 12 8.7 12
12 7/8 9.4 2.25 12 10.2 12

Type A

Type B
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II. Transportation and Storage

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II. Transportation and Storage

1. Transportation

1.1 Precautions for safety

(1) Take care not to damage painting surfaces of valves during transportation,
which may subsequently cause corrosion or rust. Damaged surfaces shall be
adequately reworked before installation.

(2) Take care when handling and storing carton packed products. The high
humidity may damage the cartons.

1.2 Transportation

1.2.1 Keep packages as they are delivered until just before installation.

1.2.2 Handle valves carefully so that they may not fall or drop on the ground. Any
extraordinary mechanical impact shall be avoided.
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Ⅱ. Transportation and Storage

2. Storage

2.1 Precautions for safety

(1) DO NOT store valves in the corrosive environment. It may cause corrosion
on the threaded portions of valves.

(2) DO NOT remove the protection cover until installation. Protection covers
prevent foreign objects, which may damage the disc or seat, from entering
into the valve internal.

(3) DO NOT place any objects on the valve or DO NOT step on the valve.
Overloading may damage the valve.

(4) DO NOT carelessly pile up products. Risk of product damage and personal
injury caused by unstable piling shall be avoided.

2.2 Storage

2.2.1 Store valves in a dust-free, least humid and well ventilated place.
Indoor storage is recommended.

2.2.2 Storage of valves directly on the ground or concrete floor is not recommended.
Valves shall be placed on a rack for storage.

2.2.3 Take appropriate measures to prevent valves from direct exposure to dust, rain and
sunlight, if stored outdoors.
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III. Valve Installation

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III. Valve Installation

1. Precautions for safety

(1) Check the valve specifications with catalogs or section 3 in chapter I of this
manual before installation. Service beyond the valve specifications may
cause fluid leakage and valve malfunctions.

(1) Keep a secure footing for valve installation and operation.

(2) Sufficient lighting shall be prepared for the valve operation.

(3) Piping shall be properly supported, as needed.

(4) The following welding measures shall be applied to the pipe-flange

connections.

PROHIBIT
WELD

WELD WELD

(5) The disc shall stick out from the body face-to-face dimension when the
valve is in the open position. Install the valve properly so that the disc does
not contact the pipe end or gasket.

(6) The valve shall not be connected directly to other valves because the disc,
which is similar to the disc of a butterfly valve, sticks out from the body end
and may cause interference to the operation.

(7) Install the hinge pin vertically if the valve is installed in the horizontal
position. Refer to the figure below.

VERTICAL
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III. Valve Installation

(8) Valves may be damaged and their product lifetime may be shortened due to
fluid vortex, turbulence or pulsation at the pump outlet and the downstream
or upstream of the reducer and the elbow. It is recommended to place a
valve at a distance of at least 6 times the nominal size using an additional
pipe from the above-mentioned devices. Refer to the following figures.

REDUCER

ELBOW
D×6
D×6
D×6
PUMP

D×6

D：NOMINAL SIZE (A)

REDUCER

(9) Fluid velocity shall be less than 3.4 m/s (11.2 fps) in the case of water.

1.1 Allow sufficient space for operation, installation and subsequent maintenance of valves.

1.2 For smooth operation, inspection and maintenance, take appropriate measures for the
valves installed in a small place.

1.3 Do not install valves in a place where valve functions may be hampered by such outer
forces as vibrations.
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III. Valve Installation

2. Precautions for safety

(1) Keep off the valve lifting area to prevent personal injury caused by
unsecured valves.

(1) Be careful not to catch fingers in flanges when installing.

(2) If the flange is welded, please allow to cool to ambient temperature before
installing the valve.

(3) Welding edges of the flange shall be ground to prevent personal injury or
valve damage.

(4) Pipes shall be properly supported, if needed.

(5) Before installation, remove foreign objects such as sand, dust and welding
spatters from the connecting pipe interior.

(6) Valves shall be properly installed in accordance with the arrows indicated on
the valve body.

(7) Use connecting flanges which have no damage or deformation. Remove any
foreign objects or rusts from the flange surfaces.

(8) Align the upstream side and downstream side of the pipe accurately.
Leakage from flange connections may be caused by inaccurate alignment.

Support the pipes first for

correct alignment.

(9) When a valve is hanged by a chain block or other appropriate tools, use an
eye bolt on the valve body in nominal size 150A (6”) and over.

(10) This valve can also be used in a vertical position if the flow is upward.

(11) Use new gaskets for installation. A gasket having an inside diameter slightly
larger than the port diameter is recommended.
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III. Valve Installation

3. Installation measures

3.1 Use jack-up bolts if required to keep a space for valve installation. The space shall be 6 to
10 mm wider than the face to face dimension of the valve.

3.2 Firstly, set two bolts into the lower side of the pipe flanges without tightening them and
then install the valve between the flanges carefully. Install the gaskets into the both sides
and set two bolts into the upper side of the pipe flanges.

3.3 Tighten four of the upper and bottom bolts temporarily.

Align the pipes and the valve accurately.

3.4 Tighten all other bolts through the holes of the pipe flanges.

3.5 Tighten the bolts evenly, gradually and alternately in a star

pattern as shown below. The ends of all tightened bolts
shall equally protrude beyond the nuts.

3.6 Gradually raise the line temperature and pressure for a pilot operation. Retighten the
threaded portions as required.
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Ⅳ. Valve Operation
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IV. Valve Operation

1. Daily inspection

In order to operate valves safely and satisfactorily, perform daily inspection on the following
items.

Items to be Areas to be Inspection

Remedial Measures
Inspected Inspected Method
Visual check Retighten the flange bolts.
Flange areas
Soap water Replace the gaskets.
External Visual check Retighten each threaded portion.
Threaded portions Replace the components as
leakage Soap water required.
Visual check
Body surfaces Replace the valve.
Soap water
Valve body Auditory check Consult with a piping engineer.
Abnormal
Loosened bolts Auditory check Retighten the bolts.
noise
Vibration of pipes Auditory check Consult with a piping engineer.
Loosened
Visual check
threaded Threaded portions Retighten each threaded portion.
Tactual check
portions
Remove foreign objects.
Disassemble and inspect the
Seat leakage - -
valve components.
Replace the valve.
Disassemble and inspect the
Valve Un-smooth
Auditory check valve components.
operation operation
Replace the valve.
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Ⅳ. Valve Operation
2. Precautions for safety

(1) Wear protective items such as goggles, gloves and working boots.

(2) Take safety measures against toxic, flammable and corrosive fluids.

(3) Reduce the line pressure to the atmospheric level before retightening flange
bolts and nuts.

(4) Operators shall take protective measures to prevent direct exposure to the
fluid in case the fluid spouts out from the flange areas.

2.1 Leakage from flange area

Tighten the flange bolts evenly, gradually and alternately

in the star pattern as shown in the figure.

2.2 Possible causes of abnormal noise

The disc hits the stop pin in the open position due to a turbulent flow of the fluid.
The disc flaps the body seat due to a low flow velocity. (known as chattering)
Water hammer phenomenon

When any abnormal noise is found, disassemble and check the components such as disc, pin
or spring. Consult with a piping engineer to take appropriate measures against abnormal
noises.
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IV. Valve Operation

3. Troubleshooting

Trouble Possible Cause Measures

Loosening of the flange bolts Retighten the flange bolts and nuts.
and nuts
Leakage from gaskets Uneven tightening of the bolts Retighten the flange bolts and nuts
and nuts evenly and gradually.
Damage of the gaskets Replace the gaskets.
Leakage from seat Damage of the seat Disassemble and check the seat.
area in fully closed Deformation of the seat due to
Consult with a piping engineer.
position an external stress.
Abnormal noise and
Loosening of the bolts and nuts Retighten the bolts and nuts.
vibration
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V. Periodic Inspection
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V. Periodic Inspection
1. Periodic inspection

1.1 Conduct periodic inspections of all valves installed in the pipeline approximately once a year.

1.2 Inspect valves for smooth operation and function.

1.3 See Chapter IV “Valve Operation” for inspection items and inspection methods.

1.4 Conduct periodic inspections of valves which are not operated for long periods of time or
not daily inspected.
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Ⅴ．Periodic Inspection
2. Maintenance and inspection
When maintenance work or inspections are performed on the valve piping facility, carry out
leakage and operation tests of the valve. Internal and external seat leakage shall not be
accepted. Check for smooth operation without galling and sticking. If any problem is found,
disassemble the valve and inspect the valve components. After assembling the valve,
re-inspect the valve. The inspection results shall be satisfactory.

2.1 Precautions for safety

(1) Discharge the fluid from the pipes and reduce the line pressure to the
atmospheric level. Trapped pressure or fluid is very dangerous and may
cause accidents resulting in personal injury.

(2) Operators must take protective measures against a spouting fluid. No fire
shall be allowed in the working area.

(3) Keep off the valve lifting area to prevent personal injury caused by
unsecured valves.

(1) Wear protective items such as goggles, gloves and working boots.

(2) Keep a secure footing for valve dismantling and installation.

(3) Valves and piping systems shall be properly supported, if needed.

(4) Before dismantling a valve from the pipeline, mark the original position of the
valve body and coupled pipe flanges. Reinstall the valve aligning these marks
after assembly.

(5) Install new gaskets between the valve and flanges when mounting a valve.
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Ⅴ．Periodic Inspection
2.2 Disassembly and assembly

Disassemble and assemble the valve according to the instructions in Chapter Ⅵ of this
manual.

2.3 Test and inspection

The followings are main items required for test and inspection of valves.

2.3.1 Operation test

The disc shall move smoothly. And when the valve is fully open, the disc shall be
stopped against the stopper.

2.3.2 Shell test and seat leakage test

(1) Precautions for safety

(1) Wear protective items such as goggles, gloves and working boots.

(2) Take adequate precautions for shell test and seat leakage test.

(2) Shell test and seat leakage test

All valves are subjected to hydrostatic or pneumatic shell test and seat leakage
test at the required test pressure after assembly.
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Ⅵ. Disassembly and Assembly

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Ⅵ. Disassembly and Assembly

1. Disassembly procedure
1.1 Precautions for safety.

(1) Take protective measures against a spouting fluid and a fire.

(1) Wear protective items such as goggles, gloves and working boots.
(2) Be careful not to catch fingers in flanges.
(3) Use appropriate equipment to lift a heavy valve.

1.2 Before disassembly

1.2.1 Disassemble valves in a dust-free area.

1.2.2 Care shall be taken not to damage body seats, disc seats and gasket sealing
surfaces.

1.3 Disassembling
1.3.1 Remove the four plugs (85) from the body (1).

1.3.2 Remove the stop pin (17B) from the body (1)

1.3.3 Remove the hinge pin (17A) from the body (1) pushing some appropriate rod to the
plugged hole. When pushing the hinge pin (17A), the spring (124) shall be held toward
the disc (4).
After pulling out the hinge pin (17A), the disc (4), spring (124) and bearings (47A, 47B
and 47C) will come off.

1.3.4 Remove the disc (4), spring (124) and bearings (47A, 47B and 47C) from the body (1).
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Ⅵ. Disassembly and assembly

2. Assembly procedure
2.1 Precautions for safety

(1) Wear protective items such as goggles, gloves and working boots.

(2) No fire shall be allowed in the working area.

(3) Be careful not to catch fingers in flanges.

(4) Replace packing and gaskets with new ones for satisfactory sealing
performance.

2.2 Before assembly

2.2.1 Check all the required parts before assembly. Replace the parts or valve, if needed.

2.2.2 If parts are reused, clean the parts to remove any oil, dust, or other foreign objects.

2.2.3 Assemble valves in a dust free area.

2.2.4 Care shall be taken not to damage the body seat, disc seat and gasket contact
surfaces.

2.2.5 All the threaded parts shall be securely tightened.

2.3 Assembling
2.3.1 Install the disc (4) to the body (1).

2.3.2 Put the hinge pin (17A) into the body (1). Install the body bearing (47A), disc bearing
(47B), spring bearing (47C), disc (4) and spring (124) in order, referring to the
construction drawing on page 25. Attach both ends of spring to each disc so that the
spring force is applied to the discs.

2.3.3 Put the stop pin (17B) into the body (1).

2.3.4 Wind the seal tape around the threaded part of the plugs (85).

2.3.5 Screw the plugs (85) into the body (1) firmly.
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Ⅵ. Disassembly and Assembly

3. Typical construction

No. Part
1 BODY
4 DISC
17A HINGE PIN
17B STOP PIN
47A BODY BEARING
47B DISC BEARING
47C SPRING BEARING
75 EYE BOLT
85 PLUG
124 SPRING