Over the course of my career, I have had the opportunity to visit many countries around the globe, seeing valve stations and installations of some large-sized valves. I have witnessed some terrific installations and some horrific ones.
Some of the best valve stations I have seen happen to be in Australia. In South Australia, there is a valve station that blends into a subdivision and could be mistaken for a modern residence. It is soundproofed internally so neighbors never hear a noise or vibration from the building, and it comes complete with installed lifting cranes, walking platforms and stairs. I suspect if I had poked around even more, I might have found a shower room, kitchen and TV lounge hidden away somewhere.
Another station that springs to mind is one in eastern Canada that is an underground station complete with a regular stairway, lighting and heating, and I can fully imagine it became a nice hideaway on those bitterly cold mornings for crews looking for maintenance projects. The only thing missing was a nice sofa.
The flip side of this would be some valve pits I have seen on the east coast of the U.S., where the valves were old and massive and had been installed in tiny concrete vaults with no consideration at all for maintenance or eventual removal. They sit entombed, likely to be buried and forgotten when their service life is deemed over, as it would be too impractical and costly to remove them.
So, what makes for a good valve station? If you are not trying to win awards for interior design or comfort, the key points would be practicality and fitness for purpose, which, when considering large valves, is extremely important.
Installing a large valve is not just about bolting it into place and calling it a day. When dealing with big iron—24 inches and up—there are some serious logistics to think through. Whether it is a pressure-reducing valve, a surge valve or something more specialized, planning can save time, money and a whole lot of headaches. Here are three things to consider before the install crew shows up.
1. Room to Breathe: Space Planning
These valves are big, so make sure there is enough clearance all around for installation and ongoing service. It is not just about the footprint—it is about headroom too. At some point, someone is going to need to lift the cover off that valve. Plan for that vertical space now or regret it later. And remember, if the valve does need complete disassembly, that means not only the valve cover being removed but also the inner valve, so ensure there is enough clearance above the valve to remove the entire stem assembly.
Consider adding a crane, gantry or structural beam where a hoist can be mounted. A roof hatch above the valve chamber might not be glamorous, but it could be a lifesaver when it is time to lift that lid. It is also worth considering how a vehicle with a crane will access the hatch.
Another key consideration inside the chamber is drainage. When a large valve is opened for service, it is going to release a lot of water. A drain in the valve room or vault is not optional; it is essential.
2. Heavy Metal Needs Solid Support
These are not your average valves; they are serious pieces of equipment, and they need proper support. Depending on the size and style, you have a few options:
- Cast-in-place concrete blocks to fit directly under the valve body
- Support from both inlet and outlet flanges, particularly if no feet are present
- For larger valves (24 inches and up), many come with built-in support feet, which are typically 1.5 inches by 36 inches. Make sure those are sitting on something solid.
If you are in an earthquake-prone area, tie-downs to a concrete base are critical. Safety and seismic stability go hand in hand. This is also true if there is any chance of the valve station being subjected to pressure transients. Entire valve buildings have been pushed off their foundations during a pressure surge, so ensure that thrust blocks or whatever support option you have is engineered and installed under the direction of a certified engineer.
3. Pipe Supports & Positioning
The valve is not the only thing that needs support. The pipes leading into and out of the station need careful attention too. A good rule of thumb for pipe support spacing is:
That means a 12-inch pipe should be supported about every 6.6 feet. In addition, surge valves and relief valves can create lateral forces during operation, so they often need additional thrust support to keep them in line.
When placing isolating valves near a control valve, leave at least one pipe diameter between them. If you are using butterfly valves, ensure they are flanged to avoid interference.
Final Thoughts
Installing a large valve is a big job, but it does not have to be a hard one if you plan ahead. Think space. Think support. Think serviceability. And if there is uncertainty, do not wing it—reach out to a local valve representative. They have likely seen and solved whatever situation is being faced.
For more articles covering valves, visit pumpsandsystems.com/tags/valves.
