Large-diameter control valves are essential components in municipal water systems and key water supply infrastructure, such as dams, reservoirs, and large-scale irrigation networks. These control valves are designed with specific features that enable them to handle substantial water flow, making them essential for efficient water distribution and management. Their role is pivotal in maintaining reliable operations, ensuring smooth maintenance, and upholding the overall integrity of water supply systems. The use of large control valves ensures that these vital systems can handle high-volume demands and prevent disruptions in service.
Water demand frequently exceeds supply, especially during peak periods, requiring effective management to maintain a consistent flow. Large-diameter control valves are crucial in this context, as they are capable of handling higher flow rates, ensuring a reliable water supply during times of increased demand.
In 2002, BERMAD introduced the 24-inch M6 Control Valve. This control valve incorporates a double-chamber design, similar to the well-established 700 series, providing superior control and durability for large-scale water systems.
Following this, the M5 Series was developed, featuring a single-chamber design and a diameter range of up to 36 inches. Both series were engineered to deliver optimal performance in high-demand environments.
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The development was carried out according to the following principles:
- All BERMAD valves undergo hydraulic testing under both static and dynamic conditions before delivery to ensure reliability and performance.
- BERMAD conducts real, precise measurements (not just calculations or estimations) to determine the flow coefficient (KV/CV) for each valve. The company provides detailed specifications, including valve type, diameter, and valve opening curves. These parameters are integrated into BERMAD's Sizing Software to ensure optimal control valve sizing and to serve as a reference for future projects.
These principles dictated the need for a testing site with a flow capacity of about 10,000 m³/h. To achieve this and based on the excellent ongoing cooperation between BERMAD and Mekorot (Isreal national water company), BERMAD was able to conduct the tests in Mekorot sites. Initially testing at the "Yardanit" site, along the Jordan River, before moving to the new site located in Kfar Baruch.
The Kfar Baruch reservoir is primarily fed by rainwater, with an additional 5-10 million cubic meters of water collected annually from the "national carrier." This water is delivered through a 30-inch diameter, 5 km long pipeline under a pressure of 7-8 bar, allowing for a filling flow rate of 3,000-8,000 m³/h, with the capability to handle up to 11,000 m³/h for short periods. A motorized butterfly valve and a flow meter were installed at the Kfar Baruch site to manage and regulate the flow.
BERMAD reached an agreement and commitment with Mekorot to conduct a safe and controlled valve testing procedure. This included controlling the flow rates during BERMAD tests through Mekorot's control center.
Prior to the tests, surge protection solutions were implemented at Mekorot's existing facility by installing a 16-inch bypass pipe equipped with a quick relief valve to bypass the tested valve.
The tested valves (24", 30", 32", 36") were connected to the main 30" pipeline using connecting pipe sections (spool piece). Flow measurements were taken with two electromagnetic flow meters: one at the start of the line and the other downstream of the valve, along with an additional ultrasonic flow meter at the valve inlet. The differential pressure, as well as the upstream and downstream pressures of the tested valve, were monitored using pressure transmitters linked directly to the BERMAD data logger system. Additional parameters, such as valve travel percentage, reaction time, and noise level, were also tested.
The tests demonstrated impressive performance results for large-size control valves. At the final stage of the testing process, Mekorot purchased the BERMAD 36-inch-M5L control valve.
The comprehensive testing setup at the Kfar Baruch Mekorot site enabled a reliable evaluation of large-diameter control valve performance under realistic conditions. This testing not only met BERMAD’s rigorous standards but also provided valuable insights for the development and enhancement of future control valve designs.
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