MANUAL OF AIR VALVES

1. Introduction

Scope

This manual provides guidelines for the installation, operation, maintenance, inspection, warranty coverage, and service procedures for Air Valves used in water supply, wastewater, irrigation, and industrial pipeline systems.

Applications

Air Valves are designed to automatically release trapped air and admit air into pipelines during filling, draining, and operation. They are commonly used in:

• Water Transmission Pipelines
• Water Distribution Networks
• Irrigation Systems
• Pumping Stations
• Water Treatment Plants
• Sewage Treatment Plants
• Industrial Process Pipelines
• Fire Protection Systems

Proper use of Air Valves improves system efficiency and protects pipelines from vacuum and surge conditions.

2. Installation Guidelines

Pre-Installation Inspection

Before installation:

• Verify valve size, pressure rating, and material specifications.
• Inspect for transportation or handling damage.
• Ensure float and internal mechanism move freely.
• Remove all protective covers and packaging materials.

Pipeline Preparation

• Clean and flush the pipeline before installation.
• Remove debris, welding slag, stones, rust, and foreign particles.
• Ensure proper pipeline alignment.

Recommended Installation Location

Install Air Valves at:

• High points of pipelines.
• Long rising sections.
• Pump discharge lines.
• Locations specified in hydraulic design.

Mounting Requirements

• Install in vertical position only.
• Ensure adequate clearance for maintenance access.
• Provide isolation valve below Air Valve for servicing.
• Use proper supports where necessary.

Installation Precautions

• Ensure valve is accessible for inspection.
• Avoid installation in flooded chambers without drainage.
• Follow flow direction markings where applicable.

3. Operation Instructions

Automatic Air Release

During operation:

• Trapped air accumulates inside the valve chamber.
• Float mechanism drops.
• Air is released automatically.
• Float rises and seals the orifice when water reaches the chamber.

Air Admission

During pipeline draining or vacuum conditions:

• Float drops.
• Air enters the pipeline.
• Vacuum formation is prevented.

Operating Precautions

• Do not obstruct air outlet ports.
• Ensure vent openings remain clean.
• Operate within rated pressure limits.
• Avoid external impacts on valve body.

4. Maintenance Schedule

Monthly Inspection

• Check for leakage.
• Inspect vent openings.
• Verify proper air release operation.
• Check chamber cleanliness.

Quarterly Inspection

• Inspect float mechanism.
• Check sealing components.
• Clean accumulated deposits.
• Verify free movement of internal parts.

Annual Inspection

• Remove valve cover.
• Inspect float assembly.
• Examine sealing surfaces.
• Replace worn seals and gaskets.
• Clean internal chamber thoroughly.
• Conduct functional testing.

Recommended Spare Parts

• Float Assembly
• O-Rings
• Sealing Components
• Gaskets
• Fasteners
• Guide Components

5. Warranty Coverage

Warranty Exclusions

Warranty does not cover:

• Improper installation.
• Damage due to contaminated media.
• Physical impact or mishandling.
• Corrosion caused by unsuitable operating conditions.
• Unauthorized repairs or modifications.
• Normal wear and tear.

6. Expected Service Life

Factors Affecting Service Life

• Water Quality
• Pressure Conditions
• Frequency of Operation
• Environmental Conditions
• Maintenance Practices
• Corrosion Exposure

Regular maintenance significantly extends operational life.

7. Customer Responsibilities

The customer shall:

• Ensure correct installation location.
• Maintain periodic inspection records.
• Perform scheduled maintenance.
• Operate within specified pressure limits.
• Keep air outlets unobstructed.
• Report defects promptly.
• Follow manufacturer's operating recommendations.

Failure to comply may affect warranty eligibility.

8. Warranty Claim Procedure

Step 1 – Claim Submission

Provide:

• Purchase Order Number
• Invoice Copy
• Valve Identification Details
• Installation Date
• Description of Defect
• Photographs of Valve and Installation

Step 2 – Technical Review

The submitted information will be evaluated to determine:

• Installation compliance
• Operating conditions
• Maintenance history
• Warranty applicability

Step 3 – Inspection

Where required:

• Site inspection may be conducted.
• Valve may be requested for detailed examination.

Step 4 – Resolution

Based on technical findings:

• Repair
• Component Replacement
• Valve Replacement
• Technical Recommendation

will be provided as per warranty terms.

Safety Precautions

• Depressurize the system before maintenance.
• Never dismantle the valve under pressure.
• Wear appropriate PPE during servicing.
• Follow plant safety procedures.
• Ensure isolation valve is closed before maintenance.

Document Retention

Maintain installation records, maintenance logs, inspection reports, and warranty documentation throughout the service life of the valve for operational reference and warranty support.