Project Type: Chilled Water System Modification

Location: Basement Pump Room (Live Building)

Nature of Work: Critical HVAC Modification without System Shutdown

Project Overview

MOLTEN recently completed a high-risk chilled water system modification project in a live building’s basement pump room. The scope involved replacing existing chilled water valves on the main line—without draining the system and without interrupting the building’s ongoing operations.

Executing work of this nature inside a live HVAC system requires deep engineering expertise, precise planning, and disciplined execution. Any mistake could lead to water leakage, system imbalance, downtime, or disruption to occupants. This project stands as a strong example of MOLTEN’s capability in handling complex HVAC works under operational constraints.

Key Challenges of the Project

Working inside a basement pump room adds multiple layers of difficulty:

• Live chilled water system with no shutdown window
• High-pressure pipelines carrying chilled water
• Limited working space and access restrictions
• Zero tolerance for leakage or operational disturbance
• Strict time constraints to minimize risk exposure

The biggest challenge was to replace the valves without draining the chilled water line, ensuring uninterrupted cooling for the building at all times.

Engineering-Driven Approach

To manage the risks effectively, the project was executed using a methodical, calculation-based engineering strategy, rather than conventional trial-and-error methods.

1. Detailed Engineering Assessment

• Evaluation of existing chilled water flow conditions
• Pressure and pipe size verification
• Valve isolation strategy planning
• Risk analysis for live system intervention

2. Controlled Work Execution

• Careful removal of existing insulation around the work area
• Precision cutting and preparation of the pipeline
• Valve replacement executed with controlled isolation techniques
• Continuous monitoring to ensure no impact on system operation

3. Skilled Workforce & Supervision

• Experienced HVAC engineers and technicians deployed
• Strict supervision throughout the activity
• Step-by-step execution as per approved method statement

Scope of Work Executed

The project scope included:

• Removal of existing chilled water line insulation
• Safe dismantling of old chilled water valves
• Installation of new chilled water valves on the main line
• High-accuracy alignment and secure valve connections
• Re-insulation of the modified pipeline sections
• System verification to ensure:
  • No leakage
  • Stable flow
  • Normal operation restored immediately

All activities were completed without draining the chilled water system and without affecting the live building operations.

Safety, Accuracy & Risk Control

This project demanded absolute precision. MOLTEN followed strict safety and quality protocols:

• Zero-leak tolerance
• Continuous system observation during execution
• Controlled working sequences
• Immediate contingency readiness

Such works are only possible with strong engineering calculations, skilled manpower, and disciplined execution, all of which were successfully demonstrated during this project.

Project Outcome

• ✅ Chilled water valves replaced successfully
• ✅ No system shutdown required
• ✅ No impact on building occupants
• ✅ No leakage or operational disturbance
• ✅ Work completed within the planned timeframe

This project reinforced MOLTEN’s reputation for handling critical HVAC works in live environments, especially in basement pump rooms and high-risk zones.

Why Clients Choose MOLTEN for Live HVAC Projects

• Engineering-first approach, not shortcuts
• Proven experience in live chilled water systems
• Expertise in risk-critical HVAC modifications
• Focus on safety, accuracy, and reliability
• Ability to execute complex works without operational disruption

Looking for Similar HVAC Works?

If you are planning:

• Chilled water valve replacement in live systems
• Basement pump room HVAC modifications
• HVAC works without shutdown or drainage
• High-risk chilled water pipeline interventions

MOLTEN is equipped to deliver engineered, safe, and reliable solutions.

BACK TO ALL POSTS