BERMAD C50 User manual

Installation, Operation and
Maintenance Manual (IOM)
Combination Air Valve
For Sewage and Wastewater
Model C50

Table of Contents
General ......................................................................... Page 2
Safety ........................................................................... Page 2
Operational Data ........................................................... Page 3
Materials and Connections ............................................ Page 3
C50 Chart ..................................................................... Page 4
C50 Parts List ............................................................... Page 5
Inflow Prevention Parts List ........................................... Page 6
Surge Protection Parts List ............................................ Page 7
Unpacking and post shipment inspection ...................... Page 8
Site Preparation ............................................................. Page 8
Installation...................................................................... Page 9
Start-up and first operation ............................................ Page 10
Operation and Maintenance .......................................... Page 10
Inspection ..................................................................... Page 12
Troubleshooting ............................................................. Page 14
Disassembling and Reassembling the valve ................... Page 15
1

BERMAD C50 is a high quality combination air valve
for a variety of sewage and wastewater networks and
operating conditions. It evacuates air during pipeline
filling, allows efficient release of air and gas pockets
from pressurized pipes, and enables large volume air
intake in the event of network draining.
With its advanced aerodynamic design and double
orifice, this valve provides excellent protection against
air and gas accumulation and vacuum formation with
improved sealing at low pressure conditions.
This document is the Installation, Operation and
Maintenance manual (IOM) of this valve; it describes
the procedures required for proper usage of the valve.
Since air valves operate in pressurized waste water
networks and sewage systems with toxic or corrosive
environment, you are required to carefully read this
manual before using the valve. Handle the valve with
care and make sure to comply with all the relevant
required safety instructions and standards, general and
local.
Safety
General
2

Pressure rating ISO PN10, ANSI / ASME 150
Operating pressure range 0.1-10 bar / 1.5-150 psi
Operating temperature Water up to 60°C / 140˚F
Operational Data
Body material Glass-reinforced plastic
Inlet diameter DN50, DN80, (2”, 3”)
Connections Threaded Male and Female
BSPT, NPT
Flanged ISO PN16 or ANSI/ASME 150
Outlet types Sideways, Downwards
Additional Features:
Surge Protection (C50-SP)
Inflow Prevention (C50-IP)
Materials and Connections
3

C50 - Chart
Upper Body (2#)
Spring (13#)
Washer
(3012#)
Body (1#)
Insect Screen
Dynamic Seal
(Kinetic Orifice)
Peel Seal
(Automatic Orifice)
Cover (15#)
Float Rod
BSPT / NPT
Female Threaded
Lower
Float (11#)
4

Upper Body (#2)
Drain Elbow (#8)
Washer (#3012)
Washer (#3014)
Washer (#3012)
Extension
for drain elbow (#14)
Flushing Port
Drainage Port
Upper O-Ring (#5027)
Upper Float
Assembly (#101)
Lower
Float Assembly
(#100)
Kinetic Seal (#4)
Kinetic Plug (#6)
Upper Float (#3)
Bolt (#2065)
Peel Seal (#5)
Washer (#3005)
Cover (#15)
Hex domed nut (#3015)
Upper Float Cork (#12)
Spring (#13)
Lower Float (#11)
Body (#1)
C50 Parts List
Lower
O-Ring (#5025)
5

Inflow Seal (#61)
O-Ring
(#5013)
Inflow grid (#52)
Inflow Extension (#53)
Drain Elbow (#8)
Inflow Prevention Parts List
6

Surge grid (#52)
O-Ring (#5013)
Surge
Seal (#51)
Drain Elbow (#8)
Surge extension (#53)
Surge Protection Parts List
7

Unpacking and post shipment inspection
■Make sure that till the actual installation the valve
remains dry and clean in its original package.
■Unpack the valve and make sure that all the wrapping
materials are removed.
■Before installation it is necessary to inspect that no
damage to the valve had occurred during shipment;
do not install a damaged valve!
■Verify that the valve to be installed meets the design
specifications of the specific installation site; take
extra care and make sure that the expected system
pressure complies with the pressure rating of the valve.
■Air Valves located above ground should be protected
from freezing and vandalism.
■If the valve is to be installed in a pit, make sure that
the pit has proper drainage and sufficient dimensions
for servicing the valve.
■Flush the pipeline prior to the Air Valve installation in
order to prevent damage to the valve internals due to
large debris carried by the water during startup.
Site Preparation
8

■Sewage and wastewater pumping stations – Air relief
and vacuum prevention.
■Sewage and wastewater pipelines – Protection
agains air and gas accumulation and vacuum
formation at elevations, slope change points
and at road/river crossings.
■Municipal and industrial wastewater treatment
plants – Protection against air and gas accumulation
and vacuum formation.
Typical Applications
Installation
■Install the Air Valve as close as possible
to the pipe, at a high point of its
circumference, in vertical position
(within 5 degrees of vertical alignment) and
with its inlet facing down.
■The diameter of the pipe connecting the Air
Valve with the pipeline should be at least
equal to the Air Valve inlet diameter.
■Install a shutoff valve between
the air valve and the pipeline
for allowing easy inspection
and maintenance.
Installation instructions
9

Start-up and first operation
■Open the shutoff valve and verify that the Air Valve
connections are not leaking; if needed follow the
troubleshooting instruction section of this document.
■Please note that at the first time the valve is filled up
some water may exit through its outlet port.
■Prevent water hammer during startup and pipeline
filling by maintaining the velocity lower than 0.5m/sec
(1.6 feet/sec).
Consider adding the Surge Protection feature in systems
where higher velocity is expected.
Operation and Maintenance
Principles of Operation
Pipeline filling
During the filling process of a pipeline, high air flow is
forced out through the kinetic orifice of the air valve.
Once water enters the valve’s chamber, the float buoyed
upwards causes the kinetic orifice to close. The unique
aerodynamic structure of the valve body and float
ensures that the float cannot be closed before water
reaches the valve.
10

Pressurized Operation
During pressurized operation of the pipeline, air
accumulates in the upper part of the air valve chamber,
causing the float to gravitate downwards. This in turn
causes the automatic orifice to open, releasing the
accumulated air.
Once the air is discharged, the water level and float rise,
causing the automatic orifice to close.
Pipeline Draining
When a pipeline is drained, a negative differential
pressure is created causing atmospheric air to push the
float down. The kinetic orifice stays open and air enters
the valve chamber, preventing vacuum formation in the
pipeline.
Surge Protection (anti-slam)
The anti-slam device is fitted to the air valve outlet.
In the event of a pressure surge it partially closes
the valve’s outlet. The approaching water column
decelerates due to the resistance of the rising air
pressure in the valve.
Inflow Prevention
The inflow prevention mechanism is a Normally Closed
check device fitted on the valve’s outlet and preventing
flow of atmospheric air into the valve.
11

Inspection
The valve does not require any specific maintenance,
however a periodical inspection of the seals and flushing
of the valve are recommended for removing debris
and foreign objects. The valve’s flushing and cleaning
frequency depends on water quality and dirt-load.
Stage A. Flushing the valve:
1. Close the shutoff valve connecting the Air valve with
the main pipeline.
2. Open the drainage port, located at the lower side of
the body (Part #1), and the flushing port at the upper
side of the Body.
3. Flush the valve by discharging pressurized clean
water into the flushing port till clean water exists
through the drainage port.
4. Close the flushing and the drainage ports and
reopen the shutoff valve.
Stage B. Dismantling the valve:
(to be performed only if stage A is not sufficient for
cleaning the valve):
1. Unscrew the bolts (Part #2065) and lift the internal
sub assemblies of the valve out of the Body
(Part #1).
12

2. Clean the Body.
3. Inspect the internal sub-assemblies of the valve
(lower and upper parts) and if necessary dismantle
and clean.
4. Reassemble the cover (Part #15) and tighten the bolts
(Part #2065).
5. Close the flushing and the drainage ports and reopen
the shutoff valve.
13

Symptom Action
Leakage at the
inlet connection
Tighten the valve connection, use
thread sealant. Check whether
any part/seal is damaged.
Leakage at
the valve cover
Tighten the valve’s cover
Check the orices area for leaks.
Leakage at
the valve’s outlet
Flush the valve to remove debris,
dissemble and inspect the valve’s
orices, oats and seals.
Remove any foreign objects,
check and replace any
damaged part.
Valve does not
release air or
allow air intake
Verify that the operating pressure
does not exceed the valve’s rated
working pressure.
Check and remove foreign objects.
Clean the valve’s internal parts,
replace if necessary.
Consult Bermad if the symptom
continues.
Troubleshooting
14

Disassembling and Reassembling the valve
The C50 valve consists of two main subassemblies; the
Upper Float Assembly and the Lower Float Assembly.
Disassembling the Upper Float Assembly:
1. Release the Upper Body (Part #2) by turning
it counterclockwise, un-screw and remove it from the
Valve’s Cover (Part #15). Make sure that the internal
parts of this assembly do not fall out.
2. Inspect the Upper O-Ring (Part #5027)
and if necessary replace it with a new one.
3. Pull the float and the Kinetic Plug (Parts # 3 & 6) out of
the Upper Float cover.
4. Inspect the float’s Peel Seal (Part #5) and the Kinetic
Seal (Part #4) for wear and tear. If necessary replace
the old parts.
Reassembling the Upper Float Assembly:
1. Wet the Kinetic Seal (Part #4) with water
and install it on the Kinetic Plug (Part #6)
with its raised edges side facing downward.
See Fig. A
Fig. A
15

2. Wet the new Peel Seal (Part #5) with clean
water.
3. Use the Lower Insertion Assistance Handle
and insert the lower end of the Peel Seal
(Part #5) to its designated groove in the
Uper float (Part #3). Make sure that the
serrated side of the seal (A) is facing the
float flat side (B) as shown in the following
drawing.
See Fig. B
4. Use the Upper Insertion Assistance Handle
to conduit the loose end of the Peel Seal
(Part #5) through its designated bore in the
Kinetic Plug (Part #6) body. Pull the Upper
Insertion Assistance Handle till the upper
mushroom shape of the Peel Seal sticks
out of the Kinetic Plug upper side. Make
sure that the Peal Seal remains straight
and not folded within the bore.
5. Once the Peel Seal is correctly seated in
place cut the Insertion Assistance Handles
and discard them.
See Fig. C
A
B
Fig. B
Fig. C
16

Disassembling the Lower Float Assembly:
1. Release and remove the Cover (Part #15) by
unscrewing the M12 bolts (#2065) together with their
washers; remove the cover (Part # 15) and the Lower
O-Ring (Part #5025).
2. Release and remove the Hex dome nut (Part #3015),
the Upper Float Cork (Part #12) and then the three
washers (Part # 3012, 3014), the rod with the Lower
Float (Part #11) and the Spring (Part #13).
Inspect these parts for wear and tear. If necessary
replace the old parts.
Reassembling the Lower Float Assembly:
1. Install the Spring (Part #13) together with upper and
lower washers (Part # 3012, 3014) on the upper side of
the Rod (Part #11).
2. Install the Upper Float Cork (Part #12) together with
upper and lower washers (Part # 3012, 3014)
and lock with the Hex dome nut (Part #3015).
Fig. D
6. Connect the Kinetic Plug (Part #6) to the
Float (Part # 4) using its Snap legs in the
right orientation as shown in the following
picture. See Fig. D
7. Insert the complete float assembly to its
place in the Upper Body (Part #2).
17

3. Connect the Upper Float Assembly to the Lower
Float Assembly through the Air Valve Cover
(Part #15).
4. Reassemble the Air Valve Cover (Part #15) on
the Body (Part #1) using the M12 bolts (Part #2065)
together with their washers. Make sure that the
Lower O-Ring (Part #5025) is properly seated
between the cover and the body.
5. The valve is reassembled, perform a compete start
up procedure as described in page 10.
18