Before beginning, ensure you have all necessary tools and materials:

• Tools: Pipe cutters, wrenches, pipe insulation, pipe supports/hangers, thread sealant, pipe cleaner, deburring tool.

• Materials: New chilled water pipe (typically copper, steel, or PEX), fittings, valves, gaskets, insulation, and sealant.

• Safety Equipment: Gloves, safety glasses, and hearing protection.

Preparation steps:

• Assess the Current System: Evaluate the existing pipe and identify the section to replace.

• Shut off the System: Turn off chilled water supply and relieve pressure. Drain the lines if necessary.

• Isolate the Affected Area: Mark boundaries of the section to be replaced and isolate with shut-off valves if possible.

• Drain the System: Ensure the pipe is fully drained before beginning work.

• Cutting the Pipe: Use a cutter or saw to cut through the old pipe as close to the joint/fitting as possible.

• Disconnect Fittings: Use wrenches to disconnect fittings; for welded pipes, a cutting torch may be needed.

• Check Fittings: Inspect and clean any fittings to be reused.

• Deburring: Smooth out any cut metal edges with a deburring tool for a tight seal.

• Measure and Cut: Prepare the new pipe to the correct length/routing.

• Install New Fittings: For replacements, install new fittings with Teflon tape or thread sealant.

For brazed or welded connections:

• Brazing/Welding: Use a propane torch and brazing rods for copper, MIG/TIG welders for steel.

• Proper Alignment: Make sure the new pipe is properly aligned and supported to prevent sagging.

• Pipe Insulation: Wrap the new pipe in appropriate insulation to minimize energy loss and prevent condensation.

• Seal Joints: Use silicone or suitable gasket material for leak-proof seals.

• Pressurize: Gradually restore pressure and check with a pump or the system itself.

• Leak Inspection: Carefully inspect all joints and pipes for leaks. Correct as needed.

• Refill: Once leak-free, refill with chilled water and restore normal operation.

• Monitor: Watch system performance for hours or days to confirm stability.

• Remove Debris: Clear out old materials and tools.

• Adjust Settings: Make sure pressure and flow rates are set correctly.