There has not been any major advancement in air-valve technology since 1996 until the launch of AirFlo Variable Orifice technology, which challenges the acceptance of technology based on pedigree above advancement, states valve and pipe manufac- turer Rexus Trading MD Allistair Balutto.

To deal with recurring problems and ensure cost competitiveness and continuous developments, continuous innovation in an industry is necessary, which demands that all technologies advance, he states, advocating the switch to new technologies instead of continuing to use older solutions.

This point of view drove Rexus Trading to develop and patent its AirFlo Variable Orifice air-valve technology, which it introduced onto the market in 2011. The company notes that there is a growing demand for the technology locally and internationally.

During the technology’s development, the company reviewed more than 137 technical papers and more than 30 global patents to study existing technology and discovered a major gap in the industry with regard to solving surge and water-hammer problems in pipelines.

Subsequently, Rexus Trading developed the AirFlo technology, which offers a holistic solution to air management and the surge and water-hammer phenomena and is, therefore, readily accepted in the valves industry.

Surge occurs in a pipeline, owing to mass oscillation, where the movement of the water causes wear and tears the lining of the pipeline, Balutto explains. Water hammer occurs when a valve suddenly closes in a pipeline system and a pressure wave propagates in the pipe, which can cause pipelines to burst.

“As opposed to older technologies, which need a specific switching point in the pipeline before coming into action or were limited by a static orifice size or encumbered by complex paraphernalia before providing limited protection, the AirFlo technology holistically protects the pipeline regardless of its size and flow characteristic.”

It senses the condition of the pipeline and automatically adjusts to ensure effective protection, he notes.

Further, t

he surge-protection mechanism of the valve is not a pressure-bearing component, which renders valve maintenance free and prevents leakage when used in low-pressure applications, owing to the addition of an impact zone in the valve floats.

Balutto explains that the severity of water hammer depends on the size of the orifice before all the air has been released from the pipeline and on any change of flow velocity in the pipeline system, which results in a change in pressure.

In all current designs, the final orifice, before closure, is limited to one size, owing to the physics of the valve, whereas AirFlo’s size varies according to the conditions of the pipeline, enabling an optimum final port of discharge before water enters and, thereby, preventing the surge and water-hammer effect across a much wider range of operation.

“The technology is changing the mindset of the industry in its approach to surge and water hammer,” he stresses.

A solution for effective air management and the phenomena of surge and water hammer has been pursued by many engineers and companies, each having succeeded to varying degrees in providing a solution for either air management or the surge or the water hammer phenomenon in pipelines, Balutto points out.

“Our technology, as the latest advancement in this field, supersedes older technologies as it effectively manages the air in a pipeline system and prevents surge and water hammer from occurring regardless of the pipeline condition.”

Further, Balutto notes that the AirFlo Variable Orifice air-valve technology is 100% South African developed, designed and manufactured. “All components are manufactured locally using no imported components, thereby creating jobs.

He notes that Rexus Trading has managed to manufacture the technology as cost effectively as that of an imported valve, if not more so.

Typically, valves need to be cast to be aesthetically pleasing and achieve efficient flow characteristics. Rexus Trading, however, developed a special manufacturing process to mould the valve bodies into an aesthetically pleasing shape that is highly efficient in terms of achieving effective airflow characteristics.

The typical delivery time of the valves from China is between 8 to 12 weeks, Balutto notes, highlighting that Rexus Trading takes between one and three weeks to deliver, depending on the size of the order for items that are not in stock.

“Therefore, the cost-effective manufacturing process of the AirFlo technology has cut down on delivery time, stockholding requirements and costs,” he states.

Rexus Trading has success- fully supplied the AirFlo technology across South Africa’s border and exports to Zambia, Malawi, Mozambique, Zimbabwe, Namibia and Botswana. The company aims to enter the American market in June by participating in exhibition and trade shows, as well as the Middle Eastern market, towards the end of this year.

“There is a growing demand for the AirFlo technology in these regions,” Balutto stresses, noting that aftermarket services will be provided by educating distribution networks.

When the company introduced the technology onto the market and outlined its advancements, the technology was readily accepted, subject to education. “We are rapidly growing as one of the preferred air-valve technology suppliers in the market, owing to the benefits we provide,” states Balutto.

He notes that Rexus Trading has supplied some of the largest air valves locally and worldwide and has also extensively supplied air valves to pipeline projects in South Africa.

“It is not about the age of the company, but the experience and the innovative spirit within Rexus Trading,” Balutto says, noting that Rexus Trading has more than 122 years of valve- industry experience among its employees.