Cla-Val Pump Control Panel Case Study

Compelled by the State Water Board, an Eastern US municipal water company recently abandoned an existing surface water treatment plant and developed two new production wells for their water supply.  The project team ultimately determined that the best pump control approach was to use a combination booster pump control valve, air release valves, pressure relief valves and a control panel that could be integrated with the existing SCADA system.

The installed equipment included Cla-Val’s 60 Series Pump Control Valve, 50 Series Pressure Relief Valves, 33A High Performance Air Release Valves and the PC-22D Pump Control Panel.

Cla-Val PC-22D Electronic Pump Control Panel

The PC-22D controls the pump and valves to prevent surges in the system when the pump starts or stops. It consists of a pre-wired electrical control panel employing an integral controller (Cla-Val Model VC-22D) to sequence the pump and valves during all modes of operation. The programmable valve controller, which is housed in a NEMA 4X rated enclosure, provides protection to the pumping system from damage due to mechanical, hydraulic or power failure. The controller is unique in that its capabilities allow for either stand-alone operation or integration into a SCADA system with standard wired signals or Modbus (TCP or RTU) communications.

 Using the valve controller’s intuitive programming screens, a customized ValvApp™ was developed to operate the pump and valves, resulting in a quick transition to the new water supply. This turnkey solution offered by Cla-Val enabled the municipal water utility to put the wells in operation with the valves and control equipment coming from just one supplier.

Custom Developed Booster Pump Control ValvAppTM


New Production Well Valve Installation


Click the links below to learn more about the VC-22D Valve Controller and our Custom ValvApp™  capabilities.

Product Link

Custom ValvApp™ Overview Link

Advancements in Automatic Control Valves


Control valves have come a long way since inception

In the past decade, the control valve industry has undergone significant advances in its ability to provide greater flexibility, control and service than ever before. With the inclusion of electronic controls and other instrumentation at valve installations, an automatic control valve can now be considered a critical part of complex telemetry/SCADA and control solutions in water distribution systems.

The development of new valve control components and auxiliary products are a direct result of listening and responding to water purveyors’ operational challenges.

Control valves are great multi-taskers

Automatic control valves can do so much more than when they were first introduced to the waterworks industry in the early 20th century.  Today, you can use one valve to perform multiple functions and execute precise control strategies to get the most out of your valve investment and the system at large.

Example: By utilizing Cla-Val’s VC-22D Electronic Valve Controller, wireless communication between the valve and the utility management system is incorporated to the overall fluid delivery solution. The VC-22D can act either as a standalone valve controller or in conjunction with a SCADA system.

Using newly developed electronic pilot controls, such as the Cla-Val CRD-34 Pressure Reducing Control, enables automatic adjustment of pressure based on demand rather than fixed set points, facilitated by the controller. This optimized pressure capability improves system efficiency, prevents damage from over-pressurization and helps save water.

Control valves are problem-solvers

Cavitation can be mitigated by retrofitting automatic control valves with Cla-Val’s KO Anti-Cavitation Trim, significantly reducing that condition in applications with high-pressure differentials. Pipeline surge and water hammer can be anticipated and minimized through the use of valves equipped with special pilot systems as is seen on Cla-Val 52-03 Surge Anticipator Relief Valves. One of the most underutilized benefits that an automatic control valve can offer is the ability to include an electronic pilot system with an all-hydraulic back up.  Because a hydraulic valve uses the system pressure to operate itself, that back up will allow the valve to continue to operate, even with loss of signal and/or power to the electronics.

Automatic control valves have become MVPs in water distribution systems 

The potential to improve reliability and optimize system performance with specially equipped control valves is significant. With the recent advancements in control valve technology, valves can now be equipped with an integral X144 e-FlowMeter to add metering capability while eliminating the cost of installing an external meter. Automatic control valves can even be used to produce power if none is available at the valve site. This is done with Cla-Val X143 Series Power Generators that produce power using the hydraulic energy in a piping system to operate electronic controllers and pilots, without impacting the primary function of the valve.

The possibilities are endless

From basic functions such as pressure reducing and level control, to the most advanced applications, development of peripheral technologies has allowed the control valve to become a more valuable, multi-faceted component of today’s water systems. We expect that control capabilities will continue to grow exponentially as the necessity for efficiency and reliability of water delivery solutions becomes ever more critical.

Learn more about Cla-Val at: 

Customized Control Valve Capabilities by Cla-Val

Cla-Val is known for its ability to create solutions for unique requirements in fluid control applications.  In fact, it’s one of the things we do best. Our customers’ need for specialized solutions is the reason why we have a large, in-house Engineering team.  It is also why we have one of the strongest R&D teams in the control valve industry. Cla-Val does more than supply standard fluid control products; we set the standard for innovative fluid control solutions.

Advanced Valve Control

A little over a year ago, we introduced the VC-22D Electronic Valve Controller to the waterworks industry. Our R&D teams in the US and Switzerland developed the VC-22D to serve as an interface between a SCADA system and other devices installed on or around a control valve. Today, the VC-22D controller is used throughout the world to improve system performance.

The VC-22D valve controller enables remote operation of electronic valves in water treatment facilities or potable water distribution systems.  As supplied, the controller is pre-loaded with fourteen of the most common valve applications (ValvApps™) to control valve and electronic device functions, including the following:


Customized Valve Control

If none of the supplied apps will meet customer requirements, Cla-Val engineers have the ability to write custom ValvApps™ to suit any application parameters. Using a proprietary development environment call “R-Designer”, programs can be customized with multiple PID functions, totalizers, metering functions, various alarms, control curves, numerous timers, or any advanced logic system requirement.

Using “R-Designer”, custom graphics can be inserted into any ValvApp™. Customer logos, system indicators and timers can be added with ease to the VC-22D home screen. A simple customer sketch is all that’s required to develop a customized ValvApp™, examples of which are shown below.  After Cla-Val Engineering develops a customized app, it can easily be uploaded, even after the VC-22D controller has been installed.

Click here to learn more about custom valve control. 


July Photo Contest Winners

Thank you to everyone who submitted photos for our contest. We had a lot of great submissions it was hard to choose just 3!

First Place: Kemtag Enterprises LTD

Photo: Booster Pump Station in Atlantic Canada

Using Cla-Val 90-01 Pressure Reducing Valves and a 60-11 Pump Control Valve

Submitted by Todd Elliott


Serving: The Canadian Provinces of New Brunswick • Newfoundland • Labrador • Nova Scotia and Prince Edward Island Phone: 506-852-4004  • Email:

Second Place: DM Valves & Controls, Inc.

Photo: Water Pumping Station in Quebec Canada

Using four Cla-Val 24” 650-03 Pump Control Valves

Submitted by Michael McAleer


Serving: The Canadian Province of Quebec Phone: 514-332-4260 • Email: Website:

Third Place: Northwestern Power Equipment Co., Inc.

Photo: Flow Control and Electronic Flow Metering for Elevated Water Tank Water

Using Cla-Val 131 Series electronic Valves with Position Transmitters and Electronic Flow Meters

Submitted by Dave Kluck and Terry Estenson

Serving:  Minnesota and parts of Illinois and Wisconsin Phone: 651-628-0683 Email: & Website:

Thank you again to everyone who submitted! Stay tuned for our next contest! Visit for more information.

Sky-High Water Delivery: Fluid Control in High-Rise Buildings

 Supplying water in high-rise buildings has changed dramatically over the past few decades as architects and contractors design and build ever-taller residential and commercial structures.

In 1965, the tallest building in the world was the Empire State Building in New York City, standing at 1250 feet tall. Today, the tallest building is the Burj Khalifa in Dubai, United Arab Emirates at 2,718 feet. Even that mega-tall structure is soon to be eclipsed by the Kingdom Tower in Jeddah, Saudi Arabia, which will reach 3,280 feet tall when completed in 2019.

Buildings that are that tall face many challenges with regard to supplying domestic water for drinking, bathing and sanitation, as well as water needed for cooling and fire fighting.

Control Valve Applications in High-Rise Structures

Cla-Val Automatic Control Valves and other complementary products such as air valves and check valves are used in high-rise building domestic water, fire protection and HVAC/cooling systems in a wide variety of applications, as shown below. In a well-designed system, the valves throughout the building work in harmony to provide water at the optimum pressure for human consumption, for mechanical systems and to fight fires.


Figure 1: Master PRV Set

Domestic Water Pressure Control 

  • Pressure Reducing
  • Master Pressure Reducing Valve Sets
  • Pressure Relief
  • Pressure Sustaining



Figure 2: Fire Pump Relief Valve

Building Water Distribution System Applications

  • Surge Control
  • Flow Control
  • Pump Control
  • On-Off Solenoid Control
  • Electronic Control
  • Cavitation Control
  • Level Control for Storage Tanks
  • HVAC Chilled Water Pressure Relief


Fire Protection System Valves

  • Deluge
  • Pressure Reducing
  • Fire Pump Pressure Relief
  • Fire Pump Casing Relief
  • Pump Suction Control
  • Pipe Breach Control

Complementary Products

  • Check Valves
  • Air Release Valves
  • Air Release and Vacuum Breaker Valves

Domestic Water: Primary Applications for Resident Health, Safety and Comfort

(08) 124 Series Float Valve  // (18) 136 Solenoid Control Valve // (19) 90 Series Pressure Reducing Valve// (20) 50 Series Pressure Relief Valve // (21) CRD-L Direct Acting PRV // (22)  Fire System Pressure Reducing Valve

In domestic water systems, Pressure Reducing Valves (PRVs) are installed in multiple locations starting from initial entry into the structure through pumps (i.e. in the basement) where water pressure from city main transmission lines is reduced or increased to usable levels. From there, pressure is adjusted through booster stations located intermittently throughout the structure to ensure adequate pressures at higher elevations.  The most commonly used Cla-Val PRVs used are 90 Series Valves and the CRD-L Direct Acting PRVs.

Pressure Relief Valves are used throughout high-rise building to prevent excess pressure and to thwart pressure surges and water hammer caused by pump stops and starts.  The most commonly used Cla-Val products in high-rise for pressure relief applications are 50 Series Valves.

These, and other valves such as PRVs equipped with anti-cavitation trim to prevent noise; differential pressure relief valves used in the cooling system; and float control valves in onsite water storage tanks; all contribute to the health, safety, and comfort of the people that work and reside in high-rise buildings.

Fire Protection System Valves: The Most Important Type of Valve

The valves that are used in the fire protection system are arguably the most important valves in high-rise buildings. First, there are the workhorse valves that adjust pressures upward or downward to accommodate fire flow requirements (such as Model 90-21 PRVs, see item 22 in Figure 3 above). Also in the VIP spot are valves such as 50 Series Pressure Relief Valves and Model 50B-4KG1 Pressure Relief Valves that protect the system during pump starts and stops.


Additional Protection for Fire Fighting Sprinkler Piping 

 After the tragic events of the 9/11 World Trade Center attacks,  Cla-Val, in conjunction with the designers behind the new WTC buildings, developed the Automatic Breach Control Valve (ABCV). The ABCV automatically isolates portions of distribution piping when a catastrophic downstream breach or line break occurs. An ABCV is typically installed in commercial building water distribution systems, such as fire protection, potable water service, or chilled water circulation.

Strategically located throughout the piping network to isolate damaged portions of water systems, the ABCV prevents significant water loss and damage, allowing continued service until piping can be repaired. The Breach Control Valve is especially well-suited for high-rise building fire sprinkler systems because of the systems’ vulnerability to failure should a line break occur in the top floors, where gravity can cause fire water reserves to quickly drain. Look for Cla-Val Model 85-09-1 when considering the implementation of added fire system reliability.

Proven the World Over: Cla-Val Products for High-Rise Buildings 

One World Trade Center

We could talk all day about which control valves are the best options for ensuring optimum health, safety and comfort of residents and business tenants that live and work in high-rise structures. Perhaps the surest way to know that is to look at the choices designers and constructors the world over have chosen for their masterpieces. Tens of thousands of Cla-Val products are installed in high-rise buildings throughout the world.

From New York City, Boston, Philadelphia and Baltimore to Chicago, Miami, Atlanta, Austin and Los Angeles, skyscrapers in the US utilize Cla-Val control valves in their domestic water, fire protection piping, booster pump station and fire pump installations.


Some of the more recognizable US locations include One World Trade Center and the Bank of America Tower in New York City; Millennium Park, Chicago; Hancock Place, Boston; Westin Bonaventure, Los Angeles; and Comcast Center and Liberty Place Towers, both in Philadelphia.

It’s not just newer structures that use Cla-Val control valves. “Vintage” skyscrapers such as the Marina Towers (1964), the John Hancock Building (1969), and Willis (Sears) Tower (1974) in Chicago have counted on Cla-Val control valves for reliable domestic and fire protection water service since their beginnings and still do today.

Downtown Chicago – Marina Towers
John Hancock Building – Chicago






Proven the World Over: Cla-Val Products for High-Rise Buildings 

Burj Khalifia – Dubai

The list of international high-rises utilizing Cla-Val products reads like a “Who’s Who” in the realm of mega structures. They include the world’s tallest building – the Burj Khalifia, Dubai, United Arab Emirates; plus Petronas Towers, Kuala Lumpur Malaysia; Gran Torre Tower, Santiago, Chile; Multiple high-rise buildings in La Defense business district, Paris; Frankfurt Main Tower, Germany; Mandarin Hotel, Singapore; and Shanghai Grand Hyatt, to name a few.

The next time you are staying in a high-rise hotel, attending a meeting in commercial skyscraper, or just getting a bird’s eye view of the city you are visiting, you can bet that the domestic and fire protection systems are equipped with Cla-Val products. Enjoy the view!

Visit to see our complete product line.

Water Pressure Optimization: The time to save water is NOW!

Need further proof that it works?  Pressure Optimization (AKA Pressure Management) has been successfully implemented as a water savings tool around the world including The United Kingdom, France, Latin America, South Africa, New Zealand and Australia.  Contact Cla-Val today and ask to have your system parameters entered into our Pressure Optimizer Calculator, to start saving water now.

Contact: or call 800.722.4866.

Top Ten Reasons Why Water Companies Should Try Pressure Optimization to Save Water

 From the Pacific Northwest down to the California-Mexico border, the western US is in a prolonged state of drought, ranking anywhere between “Moderate” to “Exceptional” according to the US Drought Monitor (see Figure 1).   Similar conditions are now creeping eastward, almost completely enveloping Nevada, Arizona, Utah, Idaho and Wyoming.  The insidious fingers of drought are even reaching into states where recent heavy rainfall has been making headlines.

Saving water is like saving money.  Cutting back only when it’s scarce doesn’t make sense and is, at best, shortsighted. In the case of water, which we know to be a limited resource, striving for the optimum management of water resources makes sense all the time and sets the stage for survival in future “times of need”.

There are lots of ways to save water.  For consumers, it includes limiting outdoor watering, taking shorter showers, using low usage appliances and planting drought resistant landscape instead of water guzzling turf.  For water companies, water saving measures vary based on systems and resources.  There is, however, one solution than can be successfully implemented in nearly all water distribution systems: Pressure Optimization.

Top Ten Reasons Why Water Companies Should Try Pressure Optimization

  1. Reducing pressure will result in lower usage, minimize leaks and reduce the incidence of pipe breaks.
  2. Standard Pressure Reducing Valves (PRVs) control to a constant pressure set point at a valve outlet, regardless of changing flow rates and/or varying inlet pressure.
  3. When using standard PRVs, as demand decreases, overall system pressure will rise.  This is due to less friction in the piping network.
  4. This rise in system pressure becomes a silent water thief.  It increases water usage, delivering more water than is needed every time a consumer turns on the tap, runs their sprinkler system, etc…
  5. Increased pressure also stresses pipes resulting in leaks and more frequent pipe breaks.
  6. Pressure Optimization allows the delivery of only the pressure required to meet actual demand, no more, no less
  7. The good news is that in, most cases, pressure optimization has little or no impact on the consumer.
  8. A Pressure Optimization package on a PRV allows the valve to immediately react to a change in demand.
  9. There are two basic approaches to Pressure Optimization: Electronic and Hydraulic. Both of which can be implemented using existing valves in a distribution system.
    1. For the electronic approach, existing PRVs are retrofitted with motorized pilots and the VC-22D Valve Controller with a pre-loaded Pressure Optimization App. This app allows the user to build a customized pressure versus flow curve, which can then be implemented in the system.
    2. For the hydraulic approach to Pressure Optimization, a standard PRV can be retrofitted with a 98 Series Pilot System. This system will allow the valve to shift from higher pressure to a lower pressure at a specific corresponding flow rate.
  10. Cla-Val’s Pressure Optimization Solutions will save water.

The Time to Save Water is NOW! 

Need further proof that it works?  Pressure Optimization (AKA Pressure Management) has been successfully implemented as a water savings tool around the world including The United Kingdom, France, Latin America, South Africa, New Zealand and Australia.  Contact Cla-Val today and ask to have your system parameters entered into our Pressure Optimizer Calculator, to start saving water now.

Contact: or call 800.722.4866.

Friday Roundup: Cla-Val to acquire HyDEC, Releases new products & more

2015 has already been a big year for Cla-Val! See the years biggest stories here:


Product Announcement: The Cla-Val CRD-L Direct Acting Pressure Reducing Valve 






– Product Announcement: The Cla-Val CDS7-DO Altitude Pilot Control with Delayed Opening






– Cla-Val to acquire HyDEC, exclusive sales agent for Cla-Val in No. California, No. Nevada and Utah since 1993.





–  Cla-Val announces the launch of our website for Latin America.





Never miss another announcement from Cla-Val again! Follow us on LinkedIn, Twitter & Facebook and visit our website for any and all things Cla-Val!

Turn your control valve into a meter in a matter of minutes!

 The Cla-Val X144 e-FlowMeter puts you on the fast track to getting flow information from control valves already installed in your pipeline. This compact, retrofittable insertion flow meter uses the vortex shedding method to measure flow. The meter is inserted into the inlet tapping of a Cla-Val control valve and oriented parallel to the direction of the flow through the valve. Flow enters the meter’s measurement cylinder where it encounters a bluff body, generating vortices. The vortices deflect off a piezoelectric sensor. The sensor then counts the vortices and communicates the data to the meter’s integral circuit board.  The flow data signal is converted to a 4-20mA and communicated to a SCADA system or logging device.

The X144 e-FlowMeter can be used in areas not normally suited for flow meters such as adjacent to pipe reducers and elbows, or downstream of a gate valve.  Because it is installed in a control valve body tapping, down time is minimal and the presence of the flow meter does not impact the valve’s original function in the pipeline (for example: pressure reduction).  In fact, the X144 e-FlowMeter can be installed in a matter of minutes.

More than two-years in the making, the X144 e-FlowMeter was developed by Cla-Val’s own R&D teams in the US and Switzerland.  The X144 was tested by two independent laboratories, Utah State University and Imperial College of London, and found to be accurate to within =/- 2% of full scale.

The X144 e-FlowMeter has been on the market for about four years. Thousands of units are installed worldwide, providing accurate flow data to system operators who, in turn, use that data to diagnose shortcomings in performance, laying the groundwork for system optimization.

An example of how our e-FlowMeter can used to identify problems in a waterworks distribution system is illustrated in the following case history about a recent installation in coastal Orange County.

Case History:  Cla-Val e-FlowMeter Helps Solve Water Quality Issues for a Coastal Community

In this case, a water company in coastal Orange County struggled with water quality in a part of the community served by three pressure reducing valve (PRV) stations, but had not yet pinned down the source of the issue.

The local Cla-Val Sales Engineer was consulted for possible solutions, and ultimately recommended that an X144 e-FlowMeter be installed in one of the three PRV stations to measure flow.  After a short time in operation, e-FlowMeter readings showed that the PRV in that particular vault was not being opened as often as it needed to be for adequate flow to ensure acceptable water quality.

The added bonus for this particular valve installation was that a Cla-Val X143IP Power Generator was installed to power the electronic flow meter and the CRD-33 Electronic Pilot Control, making this a true all-in-one valve solution.

Armed with the information the X144 e-FlowMeter provided, the entire system was rebalanced to achieve the water company’s operational goals. After solving their water quality issues in the immediate area served by that PRV station, the water company determined that installing X144 e-FlowMeters at a majority of their PRV stations should become part of their standard operating procedure to deliver the water quality their customers expected and deserved.

Whether there is a problem to be diagnosed, a desire for more information from a particular valve installation, or a need to communicate flow data to a SCADA system, the Cla-Val X144 e-FlowMeter is a cost-effective means to achieve those goals.  Minimal down time, simple set-up, and highly accurate meter readings are the hallmarks of the X144.

Watch an actual X144 e-FlowMeter being installed in a matter of minutes!


Need Trouble-Free Control Valve Operation? Cla-Val Field Service is your best bet

From the Hoover Dam to offshore oil platforms, high-rise buildings and waterworks systems throughout North America, Cla-Val Field Service provides expert on-site maintenance, repairs and start-up services for automatic control valve installations. Our technicians have even serviced Cla-Val products aboard US Navy ships and aircraft carriers.

Cla-Val Field Service Capabilities

For more than 30 years, Cla-Val’s Field Service team has provided the following types of control valve related services: 

  • Start-up assistance
  • Periodic maintenance
  • Troubleshooting/Diagnostic services
  • Valve repairs
  • Field retrofits
  • Actuator repair and maintenance

  Cla-Val Service Technician Qualifications

Cla-Val Field Service Technicians have an average of over 14 years of industry experience and all are confined-space certified. Their in depth knowledge of Cla-Val’s product line allows them to diagnose and resolve issues quickly, with minimal downtime.


Cla-Val’s Field Service Technicians are also skilled troubleshooters who can assess and advise when the addition of ancillary products such as H-Style Pipeline Strainers, anti-cavitation trim or special stems can significantly extend the service life of a control valve and minimize easily preventable performance issues.

Brand specific training is important, too. Having a field service technician who is well versed in the care and upkeep of Cla-Val control valves can make all the difference when an emergency repair is needed. Not only can Cla-Val trained technicians resolve current issues, they can also make recommendations for periodic maintenance tasks that prevent future problems from occurring.

 Cla-Val Field Service Equipment and Facilities 

Our fleet of service vehicles, most equipped with cranes for heavy lifting, are fully stocked with every part for every type valve in all sizes up to 24-inches. Spare parts are readily available from the factory or at warehouses throughout the country. Each truck also has all the tools, both common and special, that are needed to service a valve.

 Cla-Val Field Service Locations

Cla-Val’s dedicated service centers in Southern California, Northern California and Elgin, Illinois, just outside of Chicago, are able to meet the service requirements in their immediate area and surrounding states.  For service needs outside those regions, many of our factory authorized Sales Agents offer similar field services and a high level of expertise in servicing Cla-Val products, backed by the factory and a network of direct Cla-Val Salesmen and Sales Engineers throughout North America. We’ve worked hard to ensure that a field service solution is never more than a phone call away.

What are the most common service issues in automatic control valves?

 Performing regular preventative maintenance can help ensure that your Cla-Val control valves operate for years with few or no issues. Annual inspections and cleaning of body ports, strainers, and stems should generally be enough to keep your valves operating smoothly.

One of the most common service issues occurs when the pilot system strainers become plugged by mineral build-up or debris. The solution is simple: Periodically inspect and clean or change-out the strainer mesh. Using the correct strainer for the application is also important.

For systems where there is a potential for larger debris in the flow, an H-Style Pipeline Strainer is an ideal solution. Installed upstream of a control valve, an H-Style Strainer is an especially beneficial preventative measure because it stops debris from reaching the valve and becoming lodged under the main valve stem, impacting valve operation or damaging internal components.

There are a myriad of other preventative maintenance steps that can be taken to keep your control valves operating efficiently and ensure years of superior performance.  When and if issues occur, enlisting the troubleshooting skills and expertise of a Cla-Val factory trained, factory-backed service technician will get your control valves back in tip-top condition and your distribution system running again at peak efficiency.

What about the rubber components in my control valve?

As a preventative measure, Cla-Val Automatic Control Valves should undergo a complete “rubber rebuild” every three years. This entails removing and replacing the diaphragm and disc in both the valve and its pilot control.

In some cases, a complete rubber rebuild may be performed more frequently, either as preferred by the water company as a preventative measure, or by necessity in systems with exceptionally high pressure and flow or very harsh water.

How do I contact the service center or service provider in my region?

On call 24 hours a day, 7 days a week, 365 days per year, Cla-Val Field Service is there when you need it, backed by nearly 80 years of valve design and manufacturing experience. Visit our website at and click on Field Service Providers to locate the provider nearest you.

Cla-Val Field Service contact information: