Our Pipe Welding Services engineers were required again at the Millennium Hotel in Kensington for Gas Pipe Fabrication and Welding Services. The Millennium Hotel underwent a significant boiler upgrade, requiring a complete overhaul of its gas supply and heating infrastructure. IDWe, a specialist in commercial pipe welding services and mechanical installations was brought in to carry out the full scope of pipework fabrication, gas feed installation, testing, and final commissioning.
With extensive experience in industrial and commercial welding services, we managed this complex project from start to finish, including supply, on-site fabrication, in-house fabrication, system integration, and compliance testing.
Gas Pipe Fabrication and Welding Services
The primary scope of work began with the fabrication and installation of gas feeds to the new boilers. We supplied all necessary pipework, including:
- Gas-rated piping
- Pipe fittings and flanges
- Bends, valves, and flange packs
Our team configured the gas line from the main isolation valves to the gas boosters and then to the gas train. We fabricated pipework on-site and in-house to match the existing infrastructure. Certified welders performed in-situ welding and installed purge and test points on each boiler run.
We supplied and installed solenoid valves. After we completed welding and fabrication, we assembled the gas train and connected it directly to each boiler.
IDWe pressure-tested and purged the new pipework to ensure full compliance with gas safety regulations. We then performed a complete gas soundness test and finished all gas pipework with high-performance paint to prevent corrosion.
We cleared the site of all redundant items and disposed of them through a fully licensed refuse and recycling facility.
Installation of 3-Way Valves
Following the initial works, IDWe was instructed to carry out additional modifications involving the supply and installation of three 50mm 3-way valves. This work included:
- Modifying existing 150mm pipework to accommodate the new 3-way valves
- Fabricating and installing associated pipework
- Integrating the new valves into the heating system
Once installed, the system was checked for leaks and performance. Again, all removed or excess materials were disposed of responsibly in accordance with waste handling standards.
Boiler Connection Fabrication and Installation
As part of the final phase, IDWe returned to the site to survey and complete the boiler connection works. We collected pre-fabricated components from the site and carried out the following:
- Fabricated flow and return headers for the three boilers
- Installed 50mm sockets for flushing valves on both headers
- Installed 50mm sockets for safety valves
- Installed 15mm sockets for pressure and temperature gauges
These headers were fabricated off-site for precise alignment, then delivered to the hotel for final installation.
Once on-site, our team connected the headers to the flow and return circuits of the boilers.
We also installed:
- Pressure and temperature gauges
- Drain and flushing valves
- Free-issue probe pockets and safety valves
- Probe pockets for BMS controls (supplied by others)
All pipework underwent a final pressure test to confirm system integrity. After successful testing, we painted the pipework and left the site in a clean and operational state.
Technical Challenges and Solutions
Working within a live hotel environment in central London posed logistical and operational challenges. Our experienced site team planned all works around guest occupancy and access restrictions, ensuring safety and minimal disruption.
Using precision pipe welding and TIG/MIG methods, we achieved gas-tight seals with full testing and documentation. Our use of in-situ welding avoided unnecessary dismantling or re-routing of existing systems.
Location & Project Summary
- Client: MCS Limited
- Location: Millennium Hotel Copthorne Tara, Kensington, London W8
- Project Type: Gas pipe welding, boiler integration and valves installation
- Contractor: IDWe Ltd, Sidcup, London
Why Choose IDWe for Commercial Pipe Welding Services?
IDWe Pipe Welding has built a solid reputation across London and the South East for delivering precision-engineered pipe welding services in commercial and industrial environments. Our clients rely on us for:
- On-site pipe fabrication and welding (TIG, MIG, MMA)
- Boiler integration and mechanical pipework systems
- High-pressure pipework installations
- Gas booster and gas train installations
- Compliance with Gas Safe and welding regulations
- Full project life cycle support: design to commissioning
Our team includes experienced welders and pipe fitters with certifications in welding and gas safety. Whether working in tight plant rooms or occupied buildings, in or out of hours, we deliver projects safely, on time, and to specification.
You can see more of our welding and fabrication work – especially for commercial flats – see our case study at pipefreezers.co.uk, we highlight additional services in pipe freezing, hot tapping, prefabrication services and valve fitting.
Would like to know more about welding? Please read our guide.
Conclusion
This boiler upgrade at the Millennium Hotel is a clear example of IDWe’s ability to deliver high-quality, code-compliant pipe welding and installation services under complex conditions. From full gas integration to precision valve and boiler connections, we handled every stage with professionalism and technical skill.
Get in Touch for Professional Pipe Welding Services
As a leading Pipe Welding Company severing Kensington W8 and the local areas.
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Can we help you? Talk to us about your project today, please call 020 8302 7644 or email info@idwe.co.uk
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