Problem: Universal Studios is developing Universal Epic Universe, a new theme park in Orlando, set to open in 2025. The project faced a significant challenge: replacing 18 underground chiller line valves in the parking lot. This complex task involved three specialized companies: Comprehensive Energy Services for mechanical contracting, National Trench Safety for trench and traffic safety equipment, and GPH Services for site development and underwater installations. The valves, buried 18-25 feet deep, required excavation near a major drainage pipe, demanding innovative solutions for water flow management and safety. NTS provided the necessary equipment to block the storm drain, CES handled the valve servicing, and GPH, subcontracted by CES, managed the underwater aspects of the installation, ensuring the project’s success despite the challenging conditions.
Solution: NTS acquired a 72- to 120-inch Cherne I-Series Test Ball Plug for a project and rented it to Comprehensive Energy Services, who hired GPH Services for its installation due to their diving expertise. GPH ensured the plug’s correct placement, vital for CES’s repair work. This plug, notable for its size and made from 100% natural rubber, is designed for durability and conformity to pipe surfaces, making it ideal for underwater use. GPH’s preparation included extensive testing and cleaning of the pipe to prevent damage. The installation, conducted by a diver in zero visibility, emphasized safety, using a five-point harness and backup air supplies, with constant team communication. The plug remained installed for four months, successfully providing the necessary access for repairs.
Result: Cody Crawford, vice president of operations for GPH Services, praised the plug’s performance, saying, “The plug worked great, just like any other Cherne plug. Its performance was exceptional, and it met all our expectations.” Similarly, Tim Kelce, an account manager for National Trench Safety, expressed excitement about a significant project, saying, “I’m installing the largest plug in the world, and that’s a pretty big deal.” The project, notable for its use of premium materials and strict safety measures, set a new standard for future large-scale engineering projects. 800-843-7584; www.cherneind.com
