AIR RELEASE AND VACUUM BREAK VALVES

INCORPORATING ESP
VARIABLE ORIFICE TECHNOLOGY

FOR UNCOMPLICATED AND EFFICIENT AIR MANAGEMENT AND SURGE PROTECTION

 VARIABLE ORIFICE TECHNOLOGY

The Problem
Air Valves are most commonly located at high points along a pipeline where they prevent cavitation
by introducing large volumes of air into the pipeline under drainage conditions.

However, this implies that the air valve orifice may be too large under air discharge conditions. Rapid
discharge of air from too large a discharge orifice relative to the pipeline diameter results in high
pressure transients (waterhammer) because of the rapid deceleration of the water at the instant the
air is fully expelled. This produces a pressure transient similar to the rapid closure of an isolator valve
along the length of the pipeline.

Conversely, if the discharge orifice is too small then surge (mass oscillation) will be created as the air
trapped in the pipeline is compressed to a certain point from whence it will act as a spring. Violent
oscillation of the liquid within a pipeline can result in possible cyclic failure.

The Challenge
Manufacturers have over the years been challenged to developed air valves that balance the need
for large volume air intake but controlled and efficient air discharge whilst accommodating for all
pipeline variables to protect both the air valves and pipelines from the damaging effect of surge and
water hammer as a result of air release. The challenge has been made greater by the complexity of
air release and the unpredictability of pipeline operation. All of these factors combined affect the
efficacy of any air valve's surge protection device.

AIRFLO Variable Air Valve Technology - The Solution

Empirical research on a variety of pipeline conditions confirms that the most critical factor that
determines the creation of surge and waterhammer on closure of the large orifice of an air valve, or
the prevention thereof, is the size of the orifice at that critical point before closure .

Research also indicates that the size of the orifice has to be balanced with the conditions within the
pipeline system as too small an orifice may dampen Waterhammer but increase Mass Oscillation
(Surge) as well as increase filling times for a pipeline whilst too large an orifice will induce
Waterhammer.

AIRFLO Variable Orifice Air Valves incorporate a Variable Floating Shuttle that automatically adjusts
the discharge outlet of the valve to the conditions within the pipeline and provides the optimum
orifice diameter at any given point during the performance of the pipeline to ensure effective air
release whilst preventing Waterhammer and substantially reducing Mass Oscillation.

The most significant advancement is the fact that the AIRFLO design does not have a stationary
and standardised orifice and is sensitive to the air outflows of the pipeline. This smooth transition
from one differential pressure to the next and the constant adjustment of the orifice size and
therefore the backpressure and the slowing down to the advancing water column as the outflow
velocities increases is of major benefit to the pipeline designer as it takes away the guess work of
whether the orifice is either too small or too large under varying pipeline operating conditions.

The action of the AIRFLO Variable Orifice is such that it will readjust itself under pump trip and
column separation conditions thereby allowing for effective air release whilst reducing the
magnitude of the surge as well as reducing the amplitude and time period of the pressure wave. This
brings the pipeline to a steady state much more rapidly and smoothly without damage to the pipeline
system.

AIRFLO’s patented Variable Orifice air valve technology is the greatest advancement into air valve
technology over the past two decades and represents the most comprehensive pipeline protection
in a compact air valve device.
 INDEX
Design Concept 1

Operation 2

Materials of Construction 3

Features and Benefits 4

Dimensions and Weights - DN 25 and DN 50 Screwed 5

Dimensions and Weights - DN 25 to DN 100 Flanged 6

Dimensions and Weights DN 150 and DN 200 Flanged 7

Dimensions and Weights DN 250 to DN 300 Flanged 8

Position and Selection 9 - 12

Air Valve Chamber Design 13 - 14

How to Specify AIR FLO Variable Orifice Air Valves 15

Special Applications and Model Numbers 16

 DESIGN CONCEPT

It is essential for an Air Release and Vacuum Break to operate effectively across the entire working
cycle of a pipeline in order to minimise pipeline operating and maintenance costs.

AIRFLO Variable Orifice Air Release and Vacuum Break Valves represent the most advanced air
valve technology currently available.

AIRFLO is a patented compact, single chamber design with minimum operating parts that
enhances performance whilst simplifying operation and solves many of the short comings of
conventional air valve designs such as:

Surge Protection
The unique and patented operating principle of AIRFLO's Variable Orifice technology ensures
that the valve automatically selects the most appropriate orifice size relevant to the pipeline
conditions to uniformly decelerate water approaching at excessive speed, thereby limiting
pressure rise upon valve closure.

In addition to limiting pressure transients, the design attenuates the magnitude and amplitude of
mass oscillation without damage to the valve or pipeline. This feature distinguishes AIRFLO from
the limitations of conventional anti slam devices that are dependant on a fixed orifice or a specific
switching pressure to activate their surge protection.

Low Pressure Sealing and Surge Damping under Operating Conditions

Surge damping of the AIRFLO under operating conditions is enhanced through the design of the
control float which maintains a specifically calculated buoyancy allowing for a specified amount of
air to be trapped in the valve chamber. This provides a cushioning benefit for pressure transients of
short duration.

This feature also ensures driptight sealing of the small orifice at extremely low operating heads.

Pressurised Air Release

Pressurised air release in the AIRFLO design is achieved by the understanding of the relationship
that exists between the size of the small orifice and the weight of the control float which ensures
effective air discharge even under high pressure conditions. The function of the small orifice is
further enhanced by the Venturi design of the small orifice which ensures that any debris that
settles on the seating area is extracted without creating blockages in the small orifice.

Flow Characteristics
AIRFLO air release and vacuum break valves feature an unobstructed large orifice and a smooth
flow path for air intake ensuring effective vacuum breaking under pipe draining conditions.

AIRFLO intake and discharge characteristics has been established through practical testing
verified by 3rd party testing and provide the highest possible efficiency of an air valve with the
same nominal diameter.
 OPERATION
a.
Air enters the valve and flows through the
annular space between the floats and the valve
body and discharges from the large orifice into
atmosphere.
The discharging air immediately impacts the
Variable Orifice Shuttle which rises as the air
differential pressure increases across the large
orifice.
c.
Liquid enters the valve and the floats and are
buoyed so that the Large Orifice is closed. The
valve will then become internally pressurised.
Air released from solution rises through the
liquid and accumulates in the valve. When the
volume of air is sufficient to displace the water,
the control float will no longer be buoyant and
will move downwards thereby opening the small
orifice and allow accumulated air to be
discharged into atmosphere.
b.
In reaction to increased air flow, the Variable
Orifice Shuttle rises further forcing air through a
narrower path, resulting in the uniform
deceleration of the approaching water due to the
resistance of rising air pressure in the valve.
The magnitude and amplitude of surge and
water hammer is reduced more rapidly and more
uniformly with the Variable Orifice principle than
conventional anti slam devices.
d.
Drainage of liquid from the valve causes Floats
to move downwards onto the Baffle Plate
assembly, thereby allowing atmospheric air
through the valve to rapidly displace draining
water in the pipeline and prevent potentially
damaging internal partial vacuum conditions.
1
 MATERIALS OF CONSTRUCTION

Top Cover Nut Top Cover

Steel S 1700 H.D. S/Steel AISI 304 alternatively
alternatively S/Steel AISI 316 S/Steel AISI 316
Variable Orifice Guide
S/Steel AISI 304 alternatively
Top Flange Bolt S/Steel AISI 316
Steel S 1700 H.D.
alternatively S/Steel AISI 316
Variable Orifice Shuttle
S/Steel AISI 304 alternatively
S/Steel AISI 316

Top Flange Assembly

Steel - Fusion Bond Epoxy Top Flange Washer
alternatively Steel S 1700 H.D.
S/Steel AISI 316 or 304 alternatively S/Steel AISI 316

Outlet Orifice O-Ring Seat

EPDM

O -Ring Seal
EPDM
Pressurised Air Discharge Orifice
S/Steel AISI 316 or 304
Outlet Orifice Sealing Float
High Density Polyethylene Press. Air Discharge Orifice Seat
EPDM

Control Float
High Density Polyethylene
Baffle Plate & Guide Assembly
Steel Fusion Bonded Epoxy
Coated
Alternatively
S/Steel AISI 316 or 304

Body
Steel Fusion Bonded Epoxy
Coated
Alternatively 304 or 316
End Connection
DN25 & DN50:
Flanged or Screwed BSP Female
DN80 to DN300:
Flanged

Note:
Top cover can be coated to prevent theft
Dissimilar materials are isolated to prevent electrolytic corrosion

2
 FEATURES & BENEFITS

AIRFLO Variable Orifice Air Valves are designed for high performance and low maintenance. The
principle of the design is to ensure, through the integrity of the materials of construction, and the
performance characteristic of each function that the optimum pipeline performance is achieved
with every installed air valve. Some of the features of AIRFLO include:
.
S/Steel Cover:
Does not deteriorate with time. Cannot be
damage by Maintenance Staff stepping on it
.

Patented Variable Orifice Technology:

Infinitely and progressively controls air
discharge and adjusts orifice outlet relative to
pipeline conditions to ensure optimum Surge
protection while providing effective air
release.

O-Ring Seal and Seat :

Dynamic seal and seat arrangement that
ensures driptight sealing without failure
regardless of operating pressure.

Direct Acting Small Orifice :

Ensure effective pressurised air release
regardless of operating pressure.

Unique keying of rubber seat to prevent

drawout under high pressure conditions

Solid Cylindrical Floats :

No distortion or wear of the float with time

Impact Zone:
Ensures driptight sealing under low pressure
conditions.

Enhances surge protection under operating

conditions.

Full Flow Areas :

Flow areas equal the nominal size of the
valve. There is no restriction to air intake and
a smooth transition of flow due to the shape
of the valve body and overall profile of the of
the valve.

3
 DIMENSIONS & WEIGHTS
DIMENSIONS
& WEIGHTS

DN 25 and DN 50 Screwed DESIGN TYPE

Variable Orifice Air Release and Vacuum Break
Valve with Automatic Surge Protection

ACCEPTABLE MEDIA
Potable Water and Raw Water

OPERATING PRESSURE RANGE

PN 16, PN 25 and PN 40
PN 64 and PN 100 Available on Request

A OPERATING TEMPERATURE RANGE

-5 O TO 80 O

SIZE RANGE
Dn25 and DN50

MATERIALS OF CONSTRUCTION
Steel Assembly, Fusion Bonded Epoxy Coated
Alternatively S/Steel 304 or 316
Seals in EPDM
Floats in High Density Polyethylene

STANDARD FACTORY TESTS

Low Head - 2 metres; Body 1.5 times PN
B
END CONNECTIONS
Screwed BSP Female
Screwed NPT Female

STANDARD DESIGN
AIRFLO’s standard design provides for functions
as standard namely:
* Unrestricted Air Intake
* Controlled Air Discharge
* Pressurised Air Discharge
* Surge Management under rapid filling
and pump trip
C conditions

Size DN Press. Rating Model No: End Connection A B C Weight

25 PN25 25 ESP 25S SA Screwed BSP Female 168 305 1" BSP 4.6
50 PN25 50 ESP 25S SA Screwed BSP Female 198 320 2" BSP 8.6
25 PN40 25 ESP 40S SA Screwed BSP Female 168 355 1" BSP 4.8
50 PN40 50 ESP 40S SA Screwed BSP Female 198 360 2" BSP 9.8

4
 DIMENSIONS & WEIGHTS

DN 25 to DN 100 Flanged DESIGN TYPE

Variable Orifice Air Release and Vacuum Break
Valve with Automatic Surge Protection

ACCEPTABLE MEDIA
Potable Water and Raw Water

OPERATING PRESSURE RANGE

A PN 16, PN 25 and PN 40
PN 64 and PN 100 Available on Request

OPERATING TEMPERATURE RANGE

-5 O TO 80 O

SIZE RANGE
DN25, DN50, DN80 & DN100

MATERIALS OF CONSTRUCTION
Steel Assembly, Fusion Bonded Epoxy Coated
Alternatively S/Steel 304 or 316
Seals in EPDM
Floats in High Density Polyethylene

STANDARD FACTORY TESTS

Low Head - 2 metres; Body 1.5 times PN
B
END CONNECTIONS
SABS 1123 OR BS 4505
ANSI B16.5

STANDARD DESIGN
AIRFLO’s standard design provides for functions
as standard namely:
* Unrestricted Air Intake
* Controlled Air Discharge
* Pressurised Air Discharge
* Surge Management under rapid filling
and pump trip
conditions

Size DN Press. Rating Model No: End Connection A B C Weight

80 PN16 80 ESP 16F SA Flanged 246 380 200 21
100 PN16 100 ESP 16F SA Flanged 264 405 220 23
25 PN25 25 ESP 25F SA Flanged 168 305 115 4.9
50 PN25 50 ESP 25F SA Flanged 198 360 165 9.4
80 PN25 80 ESP 25F SA Flanged 246 380 200 21
100 PN25 100 ESP 25F SA Flanged 264 405 235 23
25 PN40 25 ESP 40F SA Flanged 168 355 115 5.3
50 PN40 50 ESP 40F SA Flanged 198 360 165 9.9
80 PN40 80 ESP 40F SA Flanged 246 400 200 22.5
100 PN40 100 ESP 40F SA Flanged 264 420 235 26

5
 DIMENSIONS & WEIGHTS

DN 150 and DN 200 Flanged DESIGN TYPE

Variable Orifice Air Release and Vacuum Break
Valve with Automatic Surge Protection

ACCEPTABLE MEDIA
Potable Water and Raw Water

OPERATING PRESSURE RANGE

A PN 16, PN 25 and PN 40
PN 64 and PN 100 Available on Request

OPERATING TEMPERATURE RANGE

-5 O TO 80 O

SIZE RANGE
DN150 and DN200

MATERIALS OF CONSTRUCTION
Steel Assembly, Fusion Bonded Epoxy Coated
Alternatively S/Steel 304 or 316
Seals in EPDM
Floats in High Density Polyethylene

STANDARD FACTORY TESTS

Low Head - 2 metres; Body 1.5 times PN
B
END CONNECTIONS
SABS 1123 OR BS 4505
ANSI B16.5

STANDARD DESIGN
AIRFLO’s standard design provides for functions
as standard namely:
* Unrestricted Air Intake
* Controlled Air Discharge
* Pressurised Air Discharge
* Surge Management under rapid filling
and pump trip
conditions
C

Size DN Press. Rating Model No: End Connection A B C Weight

150 PN16 150 ESP 16F SA Flanged 400 495 285 65
200 PN16 200 ESP 16F SA Flanged 464 520 340 94
150 PN25 150 ESP 25F SA Flanged 400 510 300 67
200 PN25 200 ESP 25F SA Flanged 464 535 360 98
150 PN40 150 ESP 40F SA Flanged 400 525 300 73
200 PN40 200 ESP 40F SA Flanged 464 550 375 102

6
 DIMENSIONS & WEIGHTS

DN 250 and DN 300 Flanged DESIGN TYPE

Variable Orifice Air Release and Vacuum Break
Valve with Automatic Surge Protection

ACCEPTABLE MEDIA
Potable Water and Raw Water

A OPERATING PRESSURE RANGE

PN 16, PN 25 and PN 40
PN 64 and PN 100 Available on Request

OPERATING TEMPERATURE RANGE

-5 O TO 80 O

SIZE RANGE
DN150 and DN200

MATERIALS OF CONSTRUCTION
Steel Assembly, Fusion Bonded Epoxy Coated
Alternatively S/Steel 304 or 316
Seals in EPDM
Floats in High Density Polyethylene

STANDARD FACTORY TESTS

B Low Head - 2 metres; Body 1.5 times PN

END CONNECTIONS
SABS 1123 OR BS 4505
ANSI B16.5

STANDARD DESIGN
AIRFLO’s standard design provides for functions
as standard namely:
* Unrestricted Air Intake
* Controlled Air Discharge
* Pressurised Air Discharge
* Surge Management under rapid filling
and pump trip
conditions
C

Size DN Press. Rating Model No: End Connection A B C Weight

250 PN16 250 ESP 16F SA Flanged 640 850 405 170
300 PN16 300 ESP 16F SA Flanged 710 890 460 235
250 PN25 250 ESP 25F SA Flanged 640 860 425 185
300 PN25 300 ESP 25F SA Flanged 710 900 485 245
250 PN40 250 ESP 40F SA Flanged 640 870 450 194
300 PN40 300 ESP 40F SA Flanged 710 910 515 256

7
 POSITIONING AND SELECTION

Positioning and Selecting Air Valves

Correct air valve Positioning and Selection is a systematic approach that can be simplified by
adhering to fundamental principles as outlined below.

Positioning Air Valves

Air Valves are always firstly positioned for vacuum conditions which may result from scouring of
the pipeline, pipeline rupture or instantaneous pump stoppage causing column separation.

An air valve positioned for air intake will in most instance be correctly positioned for low pressure -
high volume air release, pressurised air release and for surge protection.

However, additional air valves may need to be located along the length of the pipeline specifically
for pressurised air release or surge protection.

Hydraulic Gradeline

1
2 6 2
2 4 3
2
Lo
8 7 5 ng
De Reservoir
Long Horizontal Sections sc
en
din
ns g
Sectio Se Scour
scending cti
Pump Scour Long A on Valve
s
Valve Scour
Valve
From the pipeline under consideration, identify:

1. Peak Points - Position air valves on all the high points which fall below the hydraulic gradeline.
Peak Points should be at least two metres below the hydraulic gradeline.
If the Peak Point/s is above the hydraulic gradeline - position air valve two metres below the point
where the Hydraulic Gradeline intersects the pipeline.
2. Decrease in Upward Slope - Position air valve where a slope decreases in the direction of flow.
3. Increase in Downward Slope - Position air valve where a slope increases in the direction of flow.
4. Long Horizontal Sections - Position air valves a minimum of every 600 metres
5. Long Ascending Sections - Position air valves a minimum of every 600 metres
6. Long Descending Sections - Position air valves a minimum of every 600 metres
7. Subsequent to a Non Return Valve
8. Between Pump and Non Return Valve - for pump applications with negative suction head.

Additional points to consider for the positioning of air valves (small orifice function):
* Bulk Water Meter - in front of bulk water meters
* Reducers - In front of concentric reducers
* On large bends - where there is a vertical rise in the pipeline

8
 POSITIONING AND SELECTION

Sizing for Air Intake

Air valves are always firstly sized for air intake (vacuum) conditions.

Peak Points (Position 1)

Identify all high points which fall below the hydraulic gradeline. Consider the more severe of the two
slopes adjacent to each peak point. Determine the maximum rate of flow that can occur in this slope
as a result of pipe rupture at the lowest elevation or, flow due to scouring.

Every Air Valve should be sized independently for each high point.

It is recommended that when sizing for scour conditions to limit the scour area to 12% of the area of
the main pipeline. For pipe rupture, the area should depending on the pipeline material be limited
to 15% of the area of the pipeline The required rate of air intake will be equivalent to that of the liquid
drainage rate. The selected valve should not exceed a negative differential of 35 kPa while drawing
in air across the large orifice.

Increase in a Downward Slope or Decrease in an Upward Slope (Positions 2 and 3)

Identify all changes in slope.

Assume a pipe rupture at the bottom of the most severe slope, or complete pump stoppage. A cavity
will form at the point of change in slope that is equal the difference in flow in the two gradients. The
rate of air flow into the pipeline should therefore equal the cavity developing rate.

Long Horizontal, Ascending and Descending Sections (Positions 4, 5 and 6)

Long horizontal sections should wherever possible be avoided. Ideally a pipeline should have a
minimum slope of 3 to 6 millimetres per metre to facilitate effective air removal.

Air Valves for these positions are generally sized primarily for Pressurised Air Release.

Subsequent to a Non Return (Check) Valve (Position 7)

Size the Air Valve based on pump discharge velocities assuming instantaneous pump trip conditions
and that the column will separate at the same rate as the pump discharge rate.
.
On Borehole Pump Applications Prior to the Non Return (Check) Valve (Position 8)
Size the Air Valve based on pump discharge velocities assuming instantaneous pump trip
conditions. Ensure that the valve provides a restricted discharge to create back pressure to the
advancing water columns on pump startup and to prevent motor burn out.

Sizing for Large Volume Air Release during Initial Filling

AIRFLO utilises a Variable Orifice that automatically and infinitely adjusts to the pipeline dynamics.
The design is such that if the air valve is correctly sized or positioned for air intake, the valve will
ensure effective air release whilst limiting the pressure rise on closure to within 1.5 times the working
pressure of the pipeline

Sizing for Pressurised Air Release

AIRFLO utilises a Direct Acting small orifice arrangement. This ensures that air that is accumulates
underneath the air valve under pipeline operating conditions regardless of the working pressure. If
the valves are correctly positioned and sized for air intake and surge conditions then, the air valve
will be correctly sized for pressurised air released.

9
 POSITIONING AND SELECTION

Sizing for Surge Conditions

AIRFLO Variable Orifice Air Valves have been specifically designed to protect the pipeline against
surge conditions; from both rapid filling as well as under pump trip conditions. AIRFLO Variable
Orifice technology automatically adjusts the outlet orifice according to the pipeline conditions and
protects the pipeline from surge and waterhammer in the following way:

Initial Filling Conditions

It is good practice to limit the filling velocity of a pipeline. However, this may not often be carried out in
practice. Every AIRFLO Variable Orifice air valve is therefore designed to accommodate
unexpected high filling velocities by damping any potential surge pressures whilst allowing for
effective air release and limiting the surge pressure in the pipeline to within the pipe’s working
pressure limits.

Generally, air valves located for air intake conditions will be sufficient for effective air release and
surge protection.

AIRFLO has simplified the valve size selection with its Sizing Selection Chart . Select the pipeline
diameter. Select the flow rate within the pipeline or velocity within the pipeline. Where the vertical
and the horizontal lines meet. This will give the flow rate within the pipeline and the valve size by
colour code.

Sizing and Positioning for Pump Trip Conditions

Air valves positioned for air intake conditions are the same ones that will have an impact under surge
and pump trip conditions. Once the air valves have been sized for air intake conditions, some of the
air valves may have to be resized for surge conditions. These locations are:

Air Valve Subsequent to a Non Return Valve

The size of an air valve determined at this location is affected by the type of Non Return (Check)
Valve utilised. The slower the closing characteristic of the Non Return Valve, the larger the vacuum
created under pump trip conditions and therefore the larger the air valve size for air intake.
Consequently, the smaller the discharge outlet has to be for effective surge protection.

If sizing for worst case scenario and assuming complete pump trip then, the air valve will be sized
based on the total pump velocity. AIRFLO has been designed to accommodate this condition and
reduce the transient to within the pipeline’s working parameters.

AIRFLO has simplified the valve size selection with its Sizing Selection Chart . Select the pipeline
diameter. Select the velocity within the pipeline due to pump trip. Where the vertical and the
horizontal lines meet. This will give the flow rate within the pipeline and the valve size by colour code.

Air Valve on Severe Peak Points

When a pump trips, the negative wave will develop from the pump towards the reservoir as the
pressure within the pipeline drops. The pressure will drop at the most severe peaks creating a
negative pressure as the water column separates. The negative pressure created under these
conditions could be more severe than originally sized for pipeline scouring conditions.

A surge analysis will reveal the most appropriate air valve size for air intake. In the absence of a
thorough surge analysis, size the air valve at these locations based on the pump velocity. Compare
with the air valve sized initially for air intake conditions. Always select the larger of the two valves.

Use the sizing chart as explained above to select an air valve.

10
 POSITIONING AND SELECTION

Air Valve Selection Graph

It is prudent when sizing Air Valves for Air Intake (Vacuum) conditions for Plastics, to limit the
negative differential pressure to 20 kPa within the pipeline. Materials such as Ductile Iron and Steel
can withstand a lower negative differential pressure of 35 kPa.

This process is simplified through the AirFlo Selection Graph. To size an air valve:

* Determine the Pipeline material and use the Air Valve Selection Graph for that material.
* Determine the flow rate or velocity due to drainage for a particular Peak Point
* From the graph, select the Pipeline Diameter and the Velocity in m/sec., or the Flow Rate in L/sec.
* Where the two points intersect, that will determine the Valve Size.

The Selection Graph accommodates for both Air Intake and Air Discharge conditions. The designer
can safely and confidently select an air valve from the graph and the pipeline will adequately be
protected from both Surge and Vacuum conditions.

Air Valve Selection Graph for PVC, HDPE and GRP Pipelines

Flow in L/sec.

Air Valve Selection Graph for Ductile Iron and Steel Pipelines

Flow in L/sec.

11
 AIR VALVE CHAMBER DESIGN

Recommended Air Valve Chamber Design

A typical Air Valve chamber should have the following considerations:

Valve Chamber
A well designed valve chamber should be designed with easy access to the valve for installation and
subsequent maintenance. Good support is required in the event of the chamber settling. It is
recommended that a layer of stone be placed under the pipe for drainage purposes.

When utilising concrete rings, utilise rings with a 1.5m diameter and with a concrete cast floor with a
minimum of a 800mm opening for the air valve accumulator.

Vents
Two vents should be installed to prevent pressure build up in the valve chamber and facilitate air
circulation and prevent stale air build up in the chamber. Further, the diameter of each vent should be
equal to or greater than the size of the air valve, a mesh with a large aperture should be placed on the
inlet to allow for effective air intake but prevent vermin from entering the valve chamber.

Isolators
Resilient Seal Gate Valve (RSV's) are the most suitable isolators for PN16 and PN25 pressure
ratings and for air valve sizes of DN80 and larger. Butterfly valves should be avoided as isolators for
air valves because they present a restriction in flow and may cause turbulence in flow towards the air
valve.

Similarly, wedge gate valves should be avoided as isolators for PN40 and higher pressure ratings. It
is recommended in these applications that single offset ball valves be used.

Full bore ball valves are cost effective and highly suitable isolators for DN25 and DN50 air valves. It
is important that an air valve isolator is fully opened during commissioning to prevent turbulence in
flow towards the air valve.

Air Valve
An air valve should always be correctly sized for the application. It is recommended for large
applications to install two smaller air valves per air valve position in place of only one large air valve.
This implies that the pipeline will always be protected to a degree if one of the air valves fails for
whatever reason.

It is sometime requested that an air valve be supplied with a bleed cock. In older designs, the bleed
cock was essential to determine if the air valve is working by opening up the bleed cock periodically
to see if air or water is released from it. With the AirFlo Variable Orifice design, the purpose of the
bleed cock serves only as a possible point to measure pressure as the design ensure effective air
release regardless of the application.

Riser
The riser towards the air valve should be equal to the air valve nominal size. It is recommend that the
riser not exceed more than 500mm in height.

Air Valve Accumulator Tee

An air valve accumulator is imperative for every air valve in order to facilitate efficient air valve
operation. The air valve accumulator tee should have a vertical branch that is either equal to or a
minimum of 1/3rd the diameter of the main pipeline diameter. The vertical branch should be flanged
for fitting of the riser to it.

12
 AIR VALVE CHAMBER DESIGN

Flange Adaptor
In the case of a flanged tee where the horizontal branches are flanged, it is recommended that at
least one flange adaptor is attached to the tee in the direction of flow. This will assist in making the
installation as easy as possible.

Coupling
It is recommended that every air valve chamber be fitted with at least two couplings. The purpose of
the couplings is to assist should there be any settling of the chamber. Should the soil be unstable and
a large amount of settling is expected then, it is recommended that four couplings be utilised with
two couplings on each end.

Vent

Air Valve Chamber

Air Valve

Isolator

Riser

Tee
Flange Adaptor
Coupling

Manifold 2 x larger than Air Valve

Crushed Rock
Recommended Installation of
two or more Air Valves for large
Recommended Standard Chamber Design diameter pipelines

Vent

Air Valve Chamber

Drain
Air Valve

Isolator
Riser

Tee

Recommended Small Diameter

Recommended Cost Effectives Concrete Chamber Design Installation

13
 SPECIAL APPLICATIONS

The standard AIRFLO Air Valve design works in a very broad spectrum and can cover most air valve
applications. There are some applications where a highly specific function is required which
requires a different or modified design. These include:

Air Release and Surge Damping but no Vacuum Break Function

These are for air valves located very close to or, above the Hydraulic Gradeline. AIRFLO provides a
compact valve design that accomplishes this function (see model description below).

Vacuum Break Function Only

It is sometimes required for an air valve to only break vacuum at a specified negative differential
pressure but not provide an air release function. AIRFLO provides a compact valve design that
accomplishes this function (see model description below).

Pressurised Air Release

There are applications such as air valves in reticulation systems, air valves prior to water meters and
in front of large diameter reducers etc, where there is a need for a small diameter single orifice air
valves to release pressurised air only.

Controlled Air Discharge

Dependant on the capability of the surge and waterhammer analysis software, there is sometimes
the request for an air valve that will allow for a small, restricted discharge port but provide a large
volume air intake. AIRFLO provides a compact valve design that accomplishes this function (see
model description below).

MODEL NUMBERS

200 ESP 16 F SA
Valve Construction
SA - Standard Construction - Steel Epoxy Coated
CA - S/Steel Construction - 304 or 316
End Connection
F - Flanged
S - Screwed Female

Pressure Rating
16 - PN16
25 - PN25
40 - PN40
Valve Series No: 64 - PN64
ESP Water Application
ERP Sewer Applications
SAV Pressurised Air Release (Single Small Orifice)
VBF Vacuum Break Function only
ARF Air Release but No Air intake
Valve Size:
25 - DN25
50 - DN50
80 - DN80
100 - DN100
150 - DN150
200 - DN200
250 - DN250
300 - DN300

14
 HOW TO SPECIFY AIRFLO

Application
AIRFLO Series ESP Variable Orifice Air Valves Suitable for Potable or Strained Raw Water

Function
The valves shall perform any of the functions or combination of functions, described below:

Pipeline filling - high volume air discharge through the large orifice
Pipeline draining - high volume air intake through the large orifice
Pipeline full and operating - Discharge of pressurised air through the small orifice
Rapid filling/ column separation- The valve shall incorporate an integral Variable Orifice
mechanism that will automatically dampen surge pressures due to rapid air discharge or the
subsequent rejoining of separated water columns.

Column deceleration and surge damping shall be achieved through the ability if the Variable Orifice
mechanism to constantly and infinitely adjust to the flow conditions within the pipeline

Designs where the surge damping device is a pressure bearing component or requires a specific
switching point or, where the varying of the outlet orifice is not achievable automatically shall not be
accepted.

Construction
The Air Valve shall be of the compact single chamber design. Body materials shall as standard be
epoxy powder coated Steel to a minimum overall thickness of 250 microns or S/Steel 304 or 316
construction on request. Valves shall have a Stainless Steel 304 Cowl and Stainless Steel 304/316
trim. The cowl shall be coated to prevent theft. The valve floats shall be cylindrical and constructed
from High Density Polyethylene.

Design
The body design of the valve shall be such that the top flange assembly and body assembly is
secured by bolts and sealed by an O-Ring seal that allows for ease and low torque assembly and/or
disassembly. The sealing arrangement shall not blowout under any operating condition.

Valves with a tie rod assembly shall not be accepted.

The discharge and intake orifice area shall be equal to the nominal size of the valve.

The Small Orifice function shall be integrally housed in the valve body chamber and the function
shall be effected by the relationship between the size of the Small Orifice and the mass of the
Control Float.

The Control Float shall have an Impact Zone to enhance the buoyancy of the float and provide a
cushioning benefit under surge conditions as well as ensure driptight sealing at operating as low as
20 kPa .

Each valve shall be supplied as standard with a Variable Orifice mechanism that will infinitely and
continuously adjust to provide surge damping in line with pipeline operating conditions. The Variable
Orifice shall limit pressure to less than 1.5 times the pipeline working pressure.

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Tel: +27 11 392 4815 Fax: +27 11 392 3740 info@airflo.co.za