Maintaining chilled water systems for London’s commercial buildings demands careful planning and specialist expertise, especially when working as a replacement butterfly valves contractor on live pipework systems. Therefore, when a client required an urgent industrial valves replacement at 63 Turnmill Street, London EC1, shutdowns were not an option.
This case study explains how our pipe freezing company delivered a safe and efficient solution. More importantly, our expert engineers completed two 150mm butterfly valves installation without a system shutdown and no disruption to services by using liquid nitrogen pipe freezing.
What Was the Replacement Butterfly Valves Project Requirement?
The client’s project involved replacing two butterfly valves on CHW Pump 10B at their commercial offices in Farringdon, London. What’s more, the chilled water system had to remain live throughout the works. The client required:
- Out-of-hours attendance
- Zero loss of system services
- Safe isolation without draining the system
- An experienced and reliable industrial valves installation company
To carry out the works, liquid nitrogen pipe freezing provided the safest and fastest solution.
Firstly, our engineers confirmed there was no flow in the chilled water pipework. This check ensured a safe ice plug formation and a controlled freeze could take place.
How Did Liquid Nitrogen Pipe Freezing Work on his Project?
Secondly, we removed a small section of insulation to access the pipe. We then fitted two freeze jackets around the pipework -one on the flow and one on the return, to isolate the planned works area. Next, we poured liquid nitrogen into each jacket, which quickly formed a solid ice plug and created a secure isolation for works to take place.
Were the Butterfly Valves Replaced Safely?
Once the ice plugs had taken hold securely, our team stripped out the two existing butterfly valves from Pump 10B efficiently. We then installed two 150mm fully lugged butterfly valves. As a butterfly valves installation company, we ensured precise alignment and sealing.
How Was the System Reinstated After Valve Replacement?
After installation, we allowed the ice plugs to thaw naturally, and our engineers then inspected all joints for leaks. Following on from this, we then efficiently reinstated pipework insulation previously removed and as well as the Pump 10B. What’s more, services resumed immediately without further adjustment. The project closed cleanly, safely, and on schedule.
What Happened During Final Site Handover?
Our team cleared all redundant materials from site and disposed of waste using a licensed recycling facility. Finally, we completed a full handover with the client.
Why Did the Client Choose Pipe Freezing Services?
Cryogenic pipe freezing services allow engineers to isolate pipework without draining systems. Furthermore, this method prevents downtime, delays, and disruption to building occupants. By choosing liquid nitrogen pipe freezing, the client avoided system shutdown entirely. As a result, services continued as normal throughout the works.
What is an Ice Plug and Why is it Effective?
An ice plug forms when liquid nitrogen rapidly freezes the water inside a pipe. This frozen section creates a temporary, solid isolation point. Because the pipe remains full, pressure and system balance stay stable. This method allows for fast valve replacement without draining or refilling.
Why Does Industrial Valves Replacement Improve System Performance?
Industrial valves replacement improves reliability and flow control immediately. New valves reduce leakage risk and support consistent system operation. Modern butterfly valves also simplify future maintenance activities. This upgrade helps facilities teams manage assets more effectively long term.
How Did This Approach Save Time and Avoid Disruption?
Pipe freezing services eliminate draining, refilling, and rebalancing time. As a result, projects complete faster than traditional isolation methods. Because the system stayed live, occupants experienced no disruption. The client avoided complaints, delays, and additional operational costs.
Related Case Study – Gate Valve Removal: Lycée Français School in South Kensington
The client required the removal of a redundant 2½” flanged gate valve on their calorifier pipework. A traditional drain-down of the system approach to replace the valve, would have created unnecessary disruption, read the full story.
Why Upgrade Butterfly Valves in Commercial Systems?
Butterfly valves experience wear through regular operation. Over time, seals degrade and performance drops. Replacing valves improves isolation reliability and energy efficiency. For deeper guidance, read our useful guide.
What Pipe Freezing Services Do We Offer?
We support hospitals, commercial buildings, and industrial sites across London, Kent, Surrey, Hampshire, Essex, East Sussex, West Sussex and beyond.
Our engineers specialise in:
- Cryogenic Pipe Freezing
- Industrial Valve Replacement services
- Professional Hot Tapping Services
- Electrical interventions including LV power installations, LED lighting upgrades and lighting maintenance
Can we help you?
If you need a reliable Pipe Freezing Company we can help, talk to the team today on 020 8302 7644.
With over 35 years’ experience, our team take pride ourselves on delivering safe and professional isolation services.
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