Valve Gearbox Repair


A 400mm gate valve fitted with a reduction gearbox was recently successfully repaired by Hydrosave in order to isolate a section of pipework to complete a major CAPEX project.

High Risk Valve: through the combination of excessive force and the gearbox reduction, the valve housing had fractured completely rendering the asset in an inoperable and dangerous state. This particular design utilises the gearbox to retain the thrust from the valve and thus only gravity was keeping the valve gate in place.

Re-engineered: Hydrosave engineers removed the gearbox in sections making sure that the valve spindle and gate remained in the closed position. The pieces were taken back to the workshop and the broken sections reverse engineered.

The gearbox was reinstalled within three days from receiving the go ahead from the client and the CAPEX project remained on target.

Hydrosave Valves Online goes live.

The Hydrosave web based reporting facility, Valves Online went live on the 2nd April 2015 with a number of clients already receiving their personal login details.

All valves assessed through the CVA (Critical Valve Assessment) programme or released using the ‘Clever Valve Release’ system will be added to Valves Online. Clients can access all the information pertaining to the asset including location,  land owner information, torque requirement to operate, position, direction of operation, number of turns to operate, marker post condition, actuator type and condition, confined space requirements, traffic management requirements, pumping, chamber cover details, photographs, GIS plots and a summary report.

Ninety percent of the information is uploaded in real-time via a bespoke PDA system enabling the client to see immediately the status of any project and login rights ensure that individuals only see information pertaining to their own assets. This is another efficiency created by the New Technology team.

For more information:


Hydrosave assists water company with proactive pre-capex project.

IMGP0057      Reserved_ReportViewerWebControl

Hydrosave recently assisted a client with valve assessments and the necessary remedial actions required to ensure a CAPEX project proceeds unhindered. The valve assessment of a section of 24” trunk main included line valves, bypass valves and washouts. The main CAPEX project is to replace failed Non Return Valves and as such the asset owner wanted confirmation that the trunk main could be fully managed with the assets available. In an earlier news post we concluded that 30% of assets to date required some form of remedial action after assessment. In the case of this client, 35% required valve release and this was completed during the same visit.

The project was completed in four days and the savings were estimated at £26k over that of replacement. Performing this upfront piece of works not only created financial savings but also ensured no delays during the main project, the risk of supply failure along with any water quality issues.

For more information visit

or Call: +44 (0)330 123 0069 to arrange a project.

Hydrosave launch UK approved injectable valve repacking material for use in potable water

Hydrosave Valve-PAK™ is an injectable sealant manufactured from a mixture of high-grade synthetic fibres and a balanced combination of lubricants and binders. It is this bespoke composition that allows for rapid deployment and a leak free result.

Valve-PAK™ has zero contaminating properties and is completely inert, the material conforms to FDA guidelines and received BS6920 accreditation on the 3rd March 2015.

Hydrosave Valve-PAK™ is currently the only approved injectable material for use in potable water as part of maintenance activities on packing glands.

Hydrosave approached a manufacturer of synthetic products to design and manufacture an injectable material to meet a specific operational requirement and achieve BS6920 accreditation. Beta tests performed on raw water sites proved very successful and thus the product was submitted for approval.

For more information visit

or Call: +44 (0)330 123 0069 to arrange a project.

Contingency Planning: Zero Interruptions to Water Supply: Improving Customer Service: Maintaining a Critical Asset

Critical Valve Assessment (CVA): is a concept that Hydrosave has continued to develop in the UK over the past 12 months, focused on improving the growing issue of inoperable line valves in the utilities sector.

The Benefits

  • 100% Confidence on Valve Status
  • Certificated Planned Maintenance
  • Less Interruptions to Supply
  • Improved SIM Scores
  • Lower TOTEX
  • A Process for Safer Valve Operations
  • Improved Programme Management

Certificated Audits

CVA comprises the temporary installation of a mobile actuator to a valve, combined with  torque data logging. Controlled torque and valve operation via a PDA is monitored and recorded. A PDF report comprises a certificate of operation showing a torque graph and number of valve turns achieved. A web based report is also provided showing site photographs, xy coordinates and a client login to view a map of all valve audits. In Scotland, topographical surveys include the elevation of each asset.


Hydrosave recommend that a valve is cycled up to 60% of its full operation to ensure a robust assessment without causing disruption to supply or water quality issues. Many customers opt for a full open and closure cycle.

  • To date, CVA has been completed on high risk assets ranging in size from 6” to 36”
  • 17% of valves surveyed are tight, requiring a torque force beyond the safe working operation of an employee or team
  • 14% have been classified as seized requiring the installation and application of Hydrosave’s patented ‘clever valve release’ service
  • 31% of all valves require some form of remedial action

Results to Date

The CVA process can be combined with Hydrosave’s patented valve release technology and injection packing service.

  • A one service valve audit – resulting in 100% of the valves assessed being made operable and ready for immediate use
  • £500,000  – saved on valve replacement costs
  • Non-intrusive and the use of no dig technology – no customers have been affected


For more information visit

or Call: +44 (0)330 123 0069 to arrange a project


Increased number of valve release projects in the waste water sector


During the last quarter, Hydrosave has seen an increase in the number of valve release projects coming from the waste water sector. Typically these are smaller in size than those seen in the clean water sector, Gate valves 6” to 15” and Plug Valves up to 12”. Recent projects have also included  the larger diameter Penstock versions.

As with all water industry valves, waste water valves seize for the same reasons, however this sector differs in respect to the following factors which are very specific to this environment:

  • Increased build-up of organic matter on the internal components
  • Increased corrosion due to vast variations in extreme pH values
  • Un-maintained or zero Cathodic Protection
  • Strangulation of internal components due to ‘ragging’
  • Worn valve seats due to storm water aggregates
  • Fats Oils and Greases
  • Lack of use due to hazardous locations

The ‘clever valve release technology’ performs in the same manner and with the same successes in all environments. However, unique to waste water valves it is proving more beneficial to fully cycle the valves simultaneously whilst applying constant frequency changes in order to fully remove the particulate build up.

There has been a 100% success rate on all valves released to date. This has saved customers significant replacement costs, maintained high quality customer service and ensured safe working practices are being adopted in difficult operational circumstances.

Hydrosave also offer Cathodic Protection surveys and solutions for assets in order to protect against further corrosion.

Collaboration between Hydrosave and Integrated Water Services (IWS) injection seals a 2m³/hour leak.

chris                                           team

During a routine reservoir examination by a Dam Inspector, it was noted that remedial works were required to stem a 2m³/h leak from the packing gland of a scour valve.

As part of an M&E framework, Integrated Water Services (IWS) commissioned Hydrosave to perform an injection repack. Under continuous pumping conditions the confined space was entered and the process completed within a very short period of time. Charlie Gowers (Project Manager – IWS) stated ‘This project wasn’t the easiest to complete due to the restricted nature of the valve and the sheer quantity of water being expelled. Once we’d set up the confined space, the Hydrosave engineer was in, out and the job completed. I’ve seen many valve repacks over the last 31 years but none matched this method for efficiency and result’.

Safe Working at Height – horizontal seized valve released

The Problem: a horizontal 600mm gate valve used to throttle pumps at a major treatment facility was seized at the 25% open position. The valve was situated 4m high and operated via a chain and wheel assembly.

YW 600mm Horizontal Scaffold

YW 600mm Horizontal Scaffold zoom

The Solution: due to the risk of possible damage to a critical asset, Hydrosave’s valve release technology was selected  due to its ability to release valves using minimal torque at levels under the safe design specification for a valve. A scaffold tower was erected around the valve, the chain hub removed and the ‘clever valve release’ system installed.

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