Baltimore County’s Innovative Valve Replacement Project

Modernizing Critical Infrastructure Through Technology

Baltimore County Water Department with support from Geiger Pump & Equipment Company is conducting a groundbreaking trial to replace maintenance-intensive cone valves with Val-Matic’s innovative Surgebuster® Check Valves. This project represents a significant shift in municipal water infrastructure management, combining modern Variable Frequency Drive (VFD) pumping technology with advanced check valve design to improve operational efficiency.

The Challenge: Aging Infrastructure and Knowledge Gap

For decades, Baltimore County has relied on cone valves to prevent water hammer in their pump systems. These valves, some as old as 60 years, require specialized knowledge and maintenance. However, the department faces several critical challenges.

The retirement of experienced maintenance staff has created a significant knowledge gap. Younger employees struggle to learn the nuances of these complex systems, particularly when some manufacturers are no longer in business or have been acquired by other companies. This skills shortage threatens the county’s ability to maintain its critical water infrastructure effectively and, with an estimated 40 to 60 cone valves across the county's system, the maintenance burden is substantial.

The Solution: Surgebuster® Check Valves

The solution emerged from a combination of technological advancement and innovative thinking. Modern pumps equipped with Variable Frequency Drives (VFDs) can now control shutdown speeds, eliminating the primary need for cone valves as flow control devices.

The Val-Matic’s Surgebuster® Check Valve offers a patented design that closes quickly based on water flow, working in harmony with VFD-controlled pumps. The valve features a disc accelerator that creates pressure to close the disc as water flow decreases, preventing water hammer without any external operation or maintenance requirements.

Key Advantages

Simplicity and Reliability: Unlike cone valves with their electric, pneumatic, or hydraulic actuators, Surgebuster® valves are entirely passive. They contain no external moving parts and require no manual, electronic, or pneumatic operation. This simplicity makes them essentially maintenance-free and eliminates the need for specialized knowledge to operate.

Simplified Installation: Surgebuster® valves require only standard flange bolt connections. There are no control panels to install, no electrical or hydraulic lines to run, and no additional space requirements for actuators. This reduces both installation time and costs.

Future-Proof Design: The solution aligns with modern pump technology and requires no specialized maintenance knowledge, making it ideal for facilities with changing workforces.

Implementation

Rigorous Planning and Testing

Before purchasing any equipment, the project team commissioned a comprehensive surge analysis. This study compared the performance of Surgebuster® valves against cone valves and other alternatives across multiple scenarios. The results confirmed that Surgebuster® valves would perform as well as or better than traditional cone valves in all cases.

Phased Rollout

The implementation began with a carefully planned trial:

At the Fullerton plant, Baltimore County installed 20-inch and 16-inch Surgebuster® valves as initial test cases. The Stratford Pump Station received a 12-inch valve to replace an existing cone valve. These installations, completed in early 2026, served as proof of concept for wider deployment.

The trial generated operational data within four weeks, providing concrete evidence of performance in real-world conditions. This data-driven approach ensured any issues were identified and addressed before broader implementation.

As their existing cone valve systems require repair, Baltimore County plans to systematically replace them with the Surgebuster® check valves.

Future Outlook

The success of this project offers valuable insight for other major municipalities operating extensive cone valve and ball valve systems. While decision-makers may be hesitant to adopt new technology, this project's methodical approach—comprehensive analysis, strategic trials, and data-driven decision-making—suggests a strong case for check valve upgrades. Ultimately, the combination of VFD technology and advanced check valve design offers a compelling alternative that addresses both financial and operational challenges faced by aging infrastructure.

Contact our team today to learn if a check valve upgrade is the right step for your infrastructure.