Our specialist hot tapping team created four new outlets on live heating and chilled water pipework without shutting down the existing systems. Here is the technical details for this case study.
How did Hot Tapping Without Shutdown Support This London Project?
Project: Hot tapping existing 125mm heating and 80mm chilled water pipework
Location: Time & Life Building, 1 Bruton Street, London, W1J
Client: Ergro Technical Services Ltd
Service: Hot tapping services
Sector: Commercial offices
Project Type: Live heating and chilled water pipework modifications
Hot Taps: 4 × 1¼” outlets
Pipework: 125mm heating and 80mm chilled water
Working Environment: Occupied commercial office
Why did Ergro Technical Services Need Commercial Hot Tapping?
Our client required new outlets to facilitate their planned works from dedicated connection points within the building. The existing heating and chilled water systems needed to remain operational throughout the project.
Therefore, our experienced hot tapping services provided a practical solution for creating the required connections without shutting down the existing systems. This approach allowed their team to progress the planned works without shutting down the existing systems.
What did the Project Involve?
Our team needed to create four new 1¼-inch outlets across two existing pipework systems.
The project included:
- Two hot taps on 125mm heating pipework
- Two hot taps on 80mm chilled water pipework
- Four new 1¼-inch outlets
- TIG welding of new threaded sockets
- Installation of quarter-turn valves
- Pressure testing to 10 bar
- Hot tapping live pipework
- Installation of capped outlets for future use
- Removal of redundant materials
The works required our engineers to access various plantrooms during normal working hours. Localised smoke detection also required isolation while the work took place.
How did our Engineers Prepare the Existing Pipework?
Our team first removed the existing insulation and cladding around each connection point. We then adapted four 1¼-inch threaded sockets to suit the existing pipework. Next, our engineers TIG welded each socket onto the heating and chilled water pipework.
This created the new connection points required for the hot tapping process. Each welded connection then received a 1¼-inch quarter-turn valve. The team connected a pump set before pressure testing each new weld.
Exactly how Does Hot Tapping Live Pipework Work?
Hot tapping allows engineers to create a new connection while an existing system remains operational. Our team installed the drilling rig onto the prepared pipework connection. The rig then created an aperture through the pipe wall. The aperture remained smaller than the full 1¼-inch outlet size, as specified for this project.
Once the aperture was complete, our engineers removed the drilling rig. They also removed the section of pipe created during the tapping process. The team then closed the valve and installed a plug into the new outlet. Lastly, this left each connection ready for future use.
Why was Hot Tapping Without System Shutdown Important?
The client needed new outlets without taking the existing heating and chilled water systems offline. Hot tapping without system shutdown provided a controlled way to modify the existing pipework. It avoided the need to drain the systems before creating the new connections.
This approach also supported the wider project without unnecessary disruption to the building’s existing services. For Commercial Property Managers, maintaining operational building services can be an important consideration. Hot tap services can therefore provide an effective option for suitable live pipework modifications.
What did the Project Achieve?
The project successfully created four new 1¼-inch outlets across the existing heating and chilled water systems. Our engineers completed two hot taps on 125mm heating pipework and two on 80mm chilled water pipework. What’s more, each new welded connection underwent pressure testing to 10 bar before the hot tapping process began.
The completed outlets provided the client with dedicated connection points for their planned works. This allowed their team to progress the next stage of the project without working directly from the existing pipework. Most importantly, the works maintained the existing heating and chilled water systems throughout the project. Lastly, the completed hot taps provided a practical solution for the building’s ongoing pipework requirements.
Why Choose an Experienced Hot Tapping Contractor?
Hot tapping requires specialist equipment, careful preparation and a strong understanding of live pipework systems. Our engineers work with existing pressurised pipework and assess the requirements before starting each project. This project involved both heating and chilled water systems within a Grade II* listed London commercial building.
Furthermore, this combination required a carefully planned approach from preparation through to completion. As an experienced hot tapping contractor, we provide specialist support for challenging commercial pipework projects. Our hot tapping services support M&E Contractors, Facilities Teams, Property Managers and Commercial Building Operators. We also provide wider pipeline services, including specialist pipe fabrication and pipework solutions.
Can Hot Tapping Support Future System Expansion?
This method can create new outlets for future pipework connections and system expansion. In this project, the new outlets remained capped and ready for future use. What’s more, this provides a practical option when a building requires additional connections without immediately modifying the entire system.
This technique can support applications including:
- pipework modifications
- system expansion
- pipeline connections
- install a new branch
- existing pipework
- minimise downtime
- continuous operation
The suitability of hot tapping depends on the pipe material, size, pressure and operating conditions. A specialist assessment should always confirm the appropriate approach.
Where do IDWe Ltd Provide Hot Tapping Services?
With more than 35 years of experience, our team provides specialist hot tapping services across London and throughout the South East. We have supported Mechanical Contractors, Facilities Managers, and building owners with our service areas across London, Kent, East Sussex, West Sussex, Essex, Hampshire, Surrey and beyond.
Our London experience includes complex commercial environments where existing building services require careful modification. For Property Managers and Facilities Teams, we understand the importance of planning work around operational buildings. We work with clients and contractors to develop practical solutions for live pipework requirements.
What is Hot Tapping?
Hot tapping creates a new connection to existing pipework while the system remains operational. The process uses specialist hot tapping equipment to create an aperture through the existing pipe. Engineers first install and test the new connection before carrying out the tapping process. This allows contractors to tap a line without completely draining or shutting down the existing system.
This technique can apply to suitable heating, chilled water and other pressurised pipework systems. Furthermore, the correct approach depends on the existing system and project requirements.
How Does Hot Tapping Compare With Pipe Freezing Services?
Hot tapping and pipe freezing can both help engineers work around existing live pipework. However, they solve different project requirements. Hot tapping creates a new connection to an existing live system. Pipe freezing temporarily isolates a section of pipe using a controlled ice plug. The best solution depends on the required outcome and existing system conditions.
Read our guide to Hot Tapping vs Pipe Freezing to understand which approach may suit your project.
Frequently Asked Questions
Can hot tapping be carried out without shutting down a heating system?
Hot tapping can create suitable new connections while an existing heating system remains operational.
Can you hot tap pressurised pipework?
Specialist engineers can carry out hot tapping on suitable pressurised pipework following appropriate assessment and preparation.
Can hot tapping be used on chilled water pipework?
This project demonstrates hot tapping on 80mm chilled water pipework. However, engineers must assess each system before confirming suitability.
What is hot tapping used for?
It can create new pipework connections, support system expansion and enable modifications to existing live systems.
Can hot tapping install a new branch connection?
This method can create a new branch connection without completely shutting down a suitable existing system.
What is the difference between hot tapping and pipeline tapping?
Pipeline tapping describes creating a connection to an existing pipeline. Hot tapping provides a method for creating that connection while the existing system remains operational.
How do you pressure test a hot tap connection?
The new welded connection should undergo appropriate pressure testing before the hot tapping process begins. For this project, our team pressure tested each weld to 10 bar.
Do you provide hot tapping services in London?
We provide specialist hot tapping services across London and support projects throughout Kent and the wider South East.
How can I arrange hot tapping services for my project?
Contact our specialist team with your pipe size, system type, location and project requirements. We can discuss the application and help determine whether hot tapping provides a suitable solution.
Related Hot Tapping Resources
How Hot Tapping Services Reduce Downtime and Costs
Discover how hot tapping can help commercial projects modify existing pipework while reducing unnecessary disruption – please read our guide.
Key Benefits of Hot Tapping Services
Explore the main advantages of using hot tapping for suitable live pipework applications – read our insight.
Need a Specialist London Hot Tapping Contractor?
If your project requires a new connection to existing live pipework, our specialist team can help. We provide hot tapping services in London and across the South East, supporting commercial buildings, M&E contractors and facilities teams.
Contact us to discuss your pipework requirements and find out whether hot tapping could provide the right solution for your project.
Need to tap a line or install a new outlet for future use? Our experienced hot tapping contractors can help.
Call 020 8302 7644 or email info@idwe.co.uk to discuss your project or request a quotation.
As a leading Commercial Contractor, we provide Hot Tapping Services, Pipe Freezing Services, Valve Fitting Services, Electrical Services and more.
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