CASE STUDY · HYDRAULIC & BESPOKE ENGINEERING

Reservoir Water Valve Refurbishment & Hose Replacement

A substantial reservoir water valve was fully refurbished after damaged hoses caused it to stop working, then rebuilt with new protected hoses and thoroughly tested before installation.

Valve Refurbishment Hydraulic Engineering Hose Assemblies Testing & Commissioning

Refurbished reservoir water valve assembly ready for testing and installation

PROJECT OVERVIEW

From a failed hydraulic connection to a fully refurbished, tested valve.

Bradford Council and Yorkshire Water approached Active Hydraulics after damaged hoses connected to a reservoir water valve had caused the valve to stop working. The valve was brought into the workshop for a full refurbishment.

The valve was stripped, cleaned and resealed before receiving a two-coat epoxy paint finish. The actuating cylinder was also fully refurbished, and new hydraulic hoses were assembled with protective sleeves.

The completed valve and new hoses were then connected and thoroughly tested at Active Hydraulics before the assembly went back to the reservoir, where our team assisted the divers with reconnecting the hoses during installation.

THE CHALLENGE

Damaged hoses had stopped the valve from working.

The damaged hydraulic hoses were the immediate problem, but the valve was given a full refurbishment rather than simply replacing the hoses. The complete assembly was stripped down so the components and internal areas could be cleaned, inspected and restored.

The valve also needed to be returned to reliable working condition before it went back into the reservoir. This meant refurbishing the actuating cylinder, fitting new protected hydraulic hoses and carrying out a thorough workshop test before the installation team and divers took over.

Strip, clean and inspect the valve assembly.
Reseal the valve and restore the finish with a two-coat epoxy paint system.
Fully refurbish the cylinder that actuates the valve.
Assemble new hydraulic hoses complete with protective sleeves.
Connect and thoroughly test the complete assembly before returning to the reservoir.

OUR APPROACH

Strip, clean, reseal, rebuild and test.

Active Hydraulics carried out a full refurbishment of the valve assembly. The valve was stripped down, cleaned and resealed, with the components prepared for rebuilding and a new two-coat epoxy paint finish.

The actuating cylinder was fully refurbished and new hydraulic hoses were assembled with protective sleeves. The valve was then rebuilt as a complete working assembly with the new hoses connected.

The completed assembly was thoroughly tested at Active Hydraulics before it went back to the reservoir. Once on site, the team assisted the divers as they connected the hoses and installed the valve back into the reservoir.

Internal view of the reservoir water valve during strip-down and inspection — The valve opened during the refurbishment, allowing the internal areas to be cleaned, inspected and resealed.

ENGINEERING FOCUS

Restoring the valve, cylinder, hoses and complete hydraulic assembly.

The work covered the complete hydraulic assembly rather than just the damaged hoses. The valve was refurbished, the actuating cylinder rebuilt, new protected hoses assembled and the finished system tested in the workshop before the reservoir installation.

Strip & cleanThe valve was dismantled so the body and internal components could be cleaned and inspected.

Reseal & paintThe valve was resealed and finished with a two-coat epoxy paint system.

Cylinder & hosesThe actuating cylinder was refurbished and new hoses were assembled with protective sleeves.

Final testThe complete valve and hose assembly was connected and thoroughly tested before installation.

Reservoir water valve components separated during refurbishment — Valve components during the refurbishment process, before the rebuilt assembly was prepared for testing.

THE RESULT

A fully refurbished valve, tested and ready for installation at the reservoir.

The failed hydraulic connection was resolved through a complete refurbishment of the valve assembly. The valve was stripped, cleaned and resealed, finished with a two-coat epoxy paint system, and rebuilt with a fully refurbished actuating cylinder and new hydraulic hoses with protective sleeves.

The complete assembly was then connected and thoroughly tested at Active Hydraulics before going back to the reservoir. Once on site, Active Hydraulics assisted the diving team as they connected the new hoses and installed the refurbished valve back into position for submerged operation.

RefurbishedValve and actuating cylinder fully refurbished, resealed and rebuilt.

ProtectedNew hydraulic hoses assembled with protective sleeves.

TestedComplete assembly thoroughly tested before the reservoir installation.

Fully assembled reservoir water valve with hydraulic hoses connected during workshop testing — Final workshop test: the refurbished valve fully assembled with new protected hoses connected before going to the reservoir, where Active Hydraulics assisted the divers with the submerged connection.

HAVE A SIMILAR ENGINEERING CHALLENGE?

Let's discuss what you need to achieve.

If you have a valve, hydraulic assembly or unusual engineering component that needs repair, refurbishment, rebuilding or testing, talk to Active Hydraulics about the application.

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