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Case Studies

Eagle Mine – Stable Pressure Control for Deep Underground Water Systems

Chief Application Engineer

Background

Deep Underground Mine Water Distribution in Michigan

Located in Michigan, USA, Eagle Mine is one of the few primary nickel mines in the United States. The mine operates an underground system accessed by a decline. Water is essential for daily operations, supporting drilling, cooling, dust suppression, and safety.

In such environments, a continuous and reliable water supply is critical to production. Any instability can directly impact equipment performance and operations. As water travels down the mine, pressure increases significantly with depth, creating extreme conditions for the water distribution system. These conditions require a pressure-control solution that maintains stable performance under high pressure differentials and fluctuating demand.
This project was implemented and commissioned by Victaulic, using BERMAD control valves as the core pressure-reducing components.

Deep Underground Mine Water Distribution in Michigan

The Challenge

Controlling Pressure Instability in a Deep Mine Water System

The legacy water system relied on multiple direct-acting pressure reducing valves (DPRVs) installed along the distribution line.

This configuration led to several critical issues:

Pressure instability (“valve hunting”) across the system
Interaction between valves causing system-wide fluctuations
Pressure spikes during low demand, damaging equipment
Insufficient pressure at peak demand, limiting operation of critical systems

As described in the system analysis, each PRV continuously reacted to upstream and downstream changes, effectively causing the entire system to work against itself.

Engineering Approach

The pressure control strategy was redesigned using BERMAD engineered pressure reduction solutions specifically developed for deep-mining applications.

The new approach included:

Deployment of pressure reduction stations based on BERMAD proportional pressure reducing valves, model 720-PD-03 combined with pilot-operated PRVs
Distribution of pressure reduction across defined depth zones
Improved hydraulic separation between control points along more than 3,000 ft of vertical drop
Reduced interaction between control points

The use of proportional pressure reducing valves enabled stable and controlled pressure reduction under extreme pressure gradients typical of deep underground mining systems. This approach improved pressure stability, reduced valve interaction, and ensured reliable operation under both low and high demand conditions.

The Solution

Stable Pressure Control with BERMAD Hydraulic Control Valves

BERMAD high-performance hydraulic control valves were selected as the core component of the PRV stations providing:

Stable Pressure Control

Precise and reliable pressure reduction across varying flow conditions
Significantly reduced pressure oscillations typical to direct-acting valves

Continuous 24/7 Operation

Robust design suitable for harsh underground environments
Proven performance under high pressure and fluctuating demand

High Availability with Full Redundancy

Dual-line PRV configuration in each station
Ability to isolate, maintain, and service valves without shutting down water supply

Modular PRV Stations

Victaulic Pre-fabricated skid-mounted units for safe and efficient underground installation
Simplified commissioning and operation

The supplied system included:

16 proportional pressure reducing valves for mining applications, model 4”-720-PD-03 (unique model by BERMAD).
16 pilot-operated pressure reducing valves, model 4”-720
32 pressure relief valves, model 2”-73Q

A total of 16 PRV stations with redundant configurations were implemented throughout the mine, ensuring uninterrupted service to all operational levels.

Implementation

The PRV stations were engineered, assembled, and supplied by Victaulic as complete modular units, designed for rapid underground deployment.

Key implementation features included:

Installation across multiple mine levels without disrupting operations
Parallel installation enabled by redundant design
On-site commissioning and system testing
Training of operational teams for simplified operation and maintenance

Results

After commissioning, the upgraded system delivered immediate, measurable improvements:

Operational Stability

Stable pressure maintained across all mine levels
Valve hunting and pressure fluctuations eliminated
Reliable water supply maintained during both low and high demand

System Reliability

Continuous operation with minimal operator intervention
No pressure-related equipment failures reported

Efficiency Improvements

Water circulation losses reduced
Approx. 6,000 gallons of water saved per day

Simplified Operation

Reduced need for manual adjustments
“Plug-and-play” operation with predictable performance

Key Takeaways

Deep mining applications require system-level pressure management rather than isolated valve solutions
Conventional direct-acting PRV configurations in deep applications may introduce instability and inefficiency
Reliable systems must support continuous 24/7 operation with full redundancy
Selecting high-quality hydraulic control valves is critical for long-term performance
Integration with experienced system partners such as Victaulic ensures successful deployment

Conclusion

The Eagle Mine project demonstrates how a well-engineered pressure reduction system, combining BERMAD control valves with advanced system design, can transform a critical utility into a stable, reliable, and efficient operation. Through collaboration with Victaulic, the upgraded system now delivers continuous water supply, improved operational reliability, and reduced environmental impact, supporting safe and efficient mining at depth.