Our team completed a gate valves replacement project at the prestigious Royal Exchange in Central London, a high-traffic commercial site for retail outlets and cafes. This project required expert coordination, precision pipe freezing techniques, and careful handling of aged pipework within an operational building environment.
Six New Gate Valves Replacement Services
Client – Polyteck Building Services Ltd
Site Location – Royal Exchange, London
Contract Duration – 1-2 days (out of hours, weekend works)
Site Location and Initial Inspection
The Royal Exchange, located in the heart of Central London, presented a challenging environment due to limited access and the sensitivity of the surrounding infrastructure. Our specialist pipe freezing engineers performed an initial assessment to identify the pipework layout and determine the safest method for gate valve replacement.
Access Preparation and Insulation Removal
Our team began by safely removing the existing hammerclad pipe insulation around the 100mm steel pipework. This exposed the area and allowed them to accurately position the freeze jackets for the replacement valve isolation process.
Pipe Freezing and Valve Isolation Process
Setting Freeze Points
To isolate each section of the pipework without draining the system, we applied liquid nitrogen freeze jackets. These were placed directly before and after each existing gate valve, effectively freezing the water and forming a solid ice plug inside the pipe.
Controlled Valve Removal and Replacement
Our engineers waited until the pipe sections fully froze and stabilised, then carefully removed the first two faulty gate valves. They installed new high-quality gate valves, securing them with the existing bolts, nuts, and washers. To ensure a tight seal and prevent future leaks, they also fitted fresh gaskets.
Repeating the Procedure and Finalising the Work
Systematic Replacement of All Valves
Our engineers repeated the same controlled procedure on the remaining four valves. At each stage, they gradually thawed the pipe freezes and thoroughly inspected the joints for any signs of leakage or pressure drops.
Reinstating Insulation and Site Clean-Up
With all six gate valves successfully replaced, we reinstated the previously removed hammerclad insulation, restoring thermal protection to the pipework. The area was cleaned and left in excellent condition, ensuring no disruption to building operations. All redundant materials and transported them to a licensed recycling and refuse facility. We followed all safety protocols and left the site in pristine condition.
Result of works
The Royal Exchange now have new gate valves and everything was left in good working order.
What Is Pipe Freezing?
Pipe freezing is a method used to temporarily isolate sections of pipework by forming a solid ice plug inside the pipe. This allows for maintenance or replacement of valves and fittings without shutting down the entire system or draining large volumes of water.
Pros and Cons of Pipe Freezing
Advantages
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Non-invasive: No need to drain or shut down the entire system.
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Time-efficient: Saves time, especially in complex or high-volume systems.
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Cost-effective: Reduces labour and material costs associated with full system isolation.
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Minimally disruptive: Ideal for commercial or occupied buildings where shutdowns are impractical.
Disadvantages
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Not suitable for all systems: Pipe freezing works best with static liquids and is limited in high-flow systems.
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Temperature-dependent: Effectiveness can vary depending on ambient temperature and pipe material.
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Requires specialist equipment: Liquid nitrogen systems and skilled engineers are essential for safe application.
To find out more, please read our guide.
Can we help you with your next project? Discover further details on IDWe Ltd’s Valve Replacement Services
Get a quote, please call 020 8302 7644 or email info@idwe.co.uk
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