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 www.hydrosave.co.uk

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 www.hydrosave.co.uk

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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New bespoke valve release vehicle


Hydrosave’s latest bespoke valve release vehicle was recently put through its paces whilst un-seizing an 18″ waste water valve. The 3.5 tonne medium wheelbase unit is equipped with an on-board compressor and generator which allows the crew to react safely to any location 24 hours a day. The ability to have all the necessary equipment on one vehicle allows us to have the functionality to react to any situation, increases efficiencies and obviously has a positive impact on our carbon footprint.

As part of a planned refurbishment project of a waste water pumping station, the tier 1 contractor submitted a proposal to the asset owner to insert a ‘tee’ section whilst replacing an NRV. This would allow the installation of an over-land pipeline and a temporary pumping system to ensure the station could continue to operate on its scheduled 9 minute pumping cycles.

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