Published on August 15, 2025
When it comes to hydrant and sprinkler systems and pumps, few components are as overlooked—and as critical—as pressure relief valves (PRVs) and pressure reduction valves. If you're managing a commercial, industrial, or mixed-use facility, understanding your obligations around five yearly servicing of pressure relief valves and reduction valves is essential—not just for compliance, but for life safety, system performance, and risk management.
In this guide, we'll break down what these valves do, why five-yearly servicing is mandated, what the testing and maintenance involves, and what can go wrong if these valves are ignored.
Why Pressure Relief and Reduction Valves Matter in Fire Protection
Pressure relief and reduction valves are the quiet protectors of your fire protection system:
Pressure Relief Valves (PRVs)
Function Recap: PRVs protect the system from overpressure by releasing excess pressure when the system goes beyond a preset limit. This prevents damage to pipes, fittings, and pump components.
What Can Go Wrong If PRVs Fail
1. System Overpressurisation
If a PRV is stuck shut or improperly calibrated, it won't release pressure when needed. In high-pressure situations—such as when fire brigade trucks boost system pressure or when pumps overperform—this can lead to rapid overpressurisation.
2. Burst Pipework or Damaged Fittings
Overpressure can rupture pipes, especially in older systems or areas with weak joints. Pipe bursts can flood plant rooms, ceiling voids, or tenancies, resulting in major water damage, property loss, and operational shutdowns.
3. Pump Damage
Without a working PRV, centrifugal pumps can suffer from back pressure damage. Bearings, seals, and impellers are all at risk—potentially disabling the pump when it's needed most.
4. False Sense of Security During Tests
Because weekly or monthly churn tests often don't reach full pressure levels, PRVs may appear functional when they're not. A seized valve may only be discovered during a real fire event—when it's already too late.
5. Insurance and Liability Issues
A non-operational PRV discovered after an incident could result in insurance claim denials or expose building owners and facility managers to litigation for neglecting system maintenance.
Pressure Reduction Valves (PRVs)
Function Recap: These valves reduce the pump discharge pressure to a manageable level for certain zones. They are crucial in multi-zone or high-rise buildings where you require a high pressure to reach the top of the building, but you don't want that same pressure at the basement. Using pressure reducing valves we can set low mid and high stage zones.
What Can Go Wrong If Pressure Reduction Valves Fail
1. Overpressurised Sprinklers and Hydrants
In systems without working reduction valves, pressure on lower floors can exceed the rating of sprinkler heads or hydrant outlets. This can cause fittings to leak, crack, or disconnect under stress, particularly during fire brigade pressure boosting.
2. Inconsistent or Insufficient Pressure in Upper Levels
If a pressure reduction valve is stuck partially closed or incorrectly set, it can throttle flow to upper floors, leaving them under-pressurised. In an emergency, this could mean sprinklers or hydrants don't discharge sufficient water to suppress fire effectively.
3. Flow Imbalance in Multi-Zone Systems
In large complexes, improperly functioning PRVs can throw off the pressure balance between zones—resulting in unpredictable system behaviour. Some areas may flood while others receive inadequate water, undermining fire suppression capabilities.
4. Delayed Building Certification or Re-Inspection Failures
Fire safety audits often include verification of zone pressures and outlet flows. A malfunctioning reduction valve can cause test failures and delay handover or occupancy permits, especially in new builds or renovations.
5. Noise and Water Hammer
When pressure isn't properly regulated, rapid changes in flow can cause vibrations and noise within the pipework, also known as water hammer. Over time, this can loosen fixtures and fatigue the pipework system.
Without proper five-yearly servicing of PRVs and reduction valves, the system risks catastrophic failure—either through burst pipes, malfunctioning sprinklers, or insufficient pressure delivery to hydrants during an emergency.
What Does the Five-Yearly Servicing Involve?
Under AS1851 (Australian Standard for Routine Service of Fire Protection Systems and Equipment), the five-yearly servicing of pressure relief valves and reduction valves is mandatory. Here's what a full service should include:
| Component | Servicing Task | Why It Matters |
|---|---|---|
| PRVs (Pressure Relief Valves) | Removal from line and full overhaul, including seat lapping, spring inspection, and setting verification | Ensures valves open at correct pressure and reseal properly |
| Pressure Reduction Valves | Bench testing and recalibration to specified downstream pressure levels | Prevents over-pressurisation downstream, ensuring consistent pressure at hydrants/sprinklers |
| Valve Seats and Seals | Inspected for corrosion, pitting, and degradation | Compromised seals cause leaks or failure to maintain pressure |
| Flow Testing (System) | System pressure is observed at various downstream points before and after service | Verifies correct functioning under real-world conditions |
| Documentation | Service records must be updated with new calibration settings and condition reports | Required for compliance and insurance validation |
What Can Go Wrong If You Skip the Five-Yearly Valve Service?
Neglecting the five yearly servicing of pressure relief valves and reduction valves isn't just a box left unticked. It leads to real, expensive, and dangerous consequences.
Realistic Scenarios:
Scenario 1: Failed Pressure Regulation in High-Rise Building
What Happened Without Apex Pumps
A pressure reduction valve (PRV) in a high-rise building failed to maintain safe pressure between floors. During a scheduled system test, excessive pressure reached the lower levels and a pipe blew out
The result:
- Emergency shut-off procedures were initiated.
- Significant water damage occurred across several floors.
- The incident triggered a large insurance claim, which was ultimately denied because maintenance records showed lapsed five-year PRV servicing.
- The building was marked non-compliant, requiring reinspection and delaying occupancy.
What Would Have Happened with Apex Pumps
Had Apex Pumps been contracted to conduct the five-yearly PRV service in accordance with AS1851, the following preventive actions would have occurred:
- Zonal pressure testing to ensure floor-to-floor balance.
- Disassembly, cleaning, overhaul and reassembly of the valve.
- Replacement of worn or seized components.
Outcome: The pressure imbalance would have been detected before failure. Pipework would have remained intact, no flooding would occur, insurance eligibility would be preserved, and the building would pass compliance testing with no delays.
Scenario 2: Seized Pressure Relief Valve Triggers Pipe Burst
What Happened Without Apex Pumps
A pressure relief valve (PRV) had not been opened or functionally tested for years. Rust and debris built up inside the valve, causing it to seize shut.
When the fire pump experienced an overrun pressure spike, the PRV failed to relieve the system pressure. A concealed ceiling pipe ruptured, resulting in:
- Flooding of tenant spaces,
- Damage to fit-outs and assets,
- Significant downtime across multiple levels,
- And complaints from commercial tenants and insurance complications.
What Would Have Happened with Apex Pumps
With Apex conducting the five-yearly PRV inspection:
- The valve would have been fully removed and bench-tested under simulated spike conditions.
- Internal debris and scale would have been cleared and replaced if necessary.
- Apex would have validated the pump controller logic to avoid overrun issues by checking start/stop behaviour and feedback systems.
Outcome: The pressure spike would be safely diverted, the pipe would hold, no water damage would occur, and business continuity would remain unaffected.
Scenario 3: Fire Brigade Boost Causes System Failure During Final Inspection
What Happened Without Apex Pumps
During a council-led fire safety inspection, the fire brigade conducted a pressure boost test to simulate an emergency event. The building's PRVs, which had not been tested for years, failed to regulate the elevated inlet pressure.
This resulted in:
- Downstream pipe rupture during the boost.
- A partial system failure right in front of auditors.
- Failure of the inspection.
- Delays in building handover to tenants and contractors, costing the developer time and money.
What Would Have Happened with Apex Pumps
Apex's approach includes:
- Simulated fire brigade inlet pressure testing as part of the five-year service.
- Verification of all downstream components and PRVs under high input pressure.
- Pressure balancing and zone-specific testing to ensure system resilience.
Apex also provides certified reporting and snapshots aligned with AS1851 documentation requirements—ideal for council and fire safety audits.
Outcome: The building would have passed on the first attempt, stakeholders would remain satisfied, and handover would proceed on schedule without reputational damage.
Legal and Compliance Ramifications
Neglecting your five yearly servicing of pressure relief valves and reduction valves could cost you:
- AS1851 Non-Compliance Penalties: Potential fines from local councils or certifiers
- Insurance Claim Denials: Failure to service can invalidate cover in the event of water damage or fire loss
- Occupancy Permit Delays: Inability to pass mandatory testing could halt tenant move-ins or project sign-offs
- Legal Liability: In a real fire, malfunctioning valves can expose owners and managers to legal action for negligence
How Apex Pumps Ensures Full Compliance
At Apex Pumps, we don't just "tick the box"—we provide benchmark-level servicing for pressure relief valves and pressure reduction valves as part of your full fire protection compliance schedule.
- On-site valve removal and reinstallation
- Bench testing in controlled conditions
- Flow testing post-install
- Detailed service documentation and calibration sheets
- Expert recommendations on valve upgrades if nearing end-of-life