IDWe Ltd’s HVAC team replaced a failed air-cooled process chiller at Darent Valley Hospital, restoring reliable cooling to the GEA Heart Centre AHU.
Project: Air-Cooled Chiller Replacement
Location: Darent Valley Hospital, Darenth Wood Road, Dartford, DA2
Service: Chiller replacement and chilled-water system upgrade
Sector: Healthcare
Works Included: Chiller installation, CHW pipework, electrical works, trace heating, insulation, controls and commissioning
Why Did Darent Valley Hospital Need a Chiller Replacement?
Darent Valley Hospital is a busy NHS hospital serving patients across Dartford and the surrounding Kent area.
The existing Carrier 30RA-80 air-cooled chiller had failed. Consequently, the hospital needed a reliable replacement serving the GEA Heart Centre AHU.
The project required careful coordination because the installation took place within a live healthcare environment.
Therefore, we coordinated the mechanical, electrical, HVAC and controls requirements as one complete project.
Which Air-Cooled Chiller did IDWe Ltd Install?
Our team supplied and installed an ICS iC538 77kW packaged air-cooled i-Chiller. The new chiller replaced the failed Carrier 30RA-80 unit in the same position. Furthermore, the installation also included a 410-litre buffer vessel and pump set.
Together, these components provided a complete packaged chiller unit for the existing chilled-water system. The air-cooled design also avoids the need for a cooling tower. Consequently, the hospital gained a practical cooling tower-free solution with fewer associated cooling tower maintenance requirements.
What did the Chiller Installation Involve?
Replacing the failed equipment required more than simply installing a new packaged chiller unit. Firstly, IDWe Ltd HAVC team decommissioned the existing Carrier chiller and recovered its R407C refrigerant. We then isolated and disconnected the existing TPN electrical supply and control cabling.
Next, our engineers drained and disconnected the existing chilled-water flow and return pipework. A Hiab crane then lifted out the existing air-cooled chiller away. The new ICS iC538 77KW was subsequently lifted into the same position. This approach allowed the replacement equipment to use the existing installation location.
Mechanical Works Completed Explained
IDWe Ltd replaced the chilled-water flow and return pipework from the new chiller to the AHU coil. The new installation included:
- Strainers
- Double regulating valves
- Bellows
- Commissioning sets
- Dosing pot
- Automatic air vents
- Gauges
- 410-litre buffer vessel
- New pump set
We then pressure-tested the new chilled-water circuit before filling it with water. Finally, our engineers commissioned the chilled-water flow rates through the new chiller. This created a complete chilled-water connection between the new chiller and the existing AHU coil.
Why Were Trace Heating and new Insulation Required?
The new chilled-water pipework required appropriate protection to support reliable operation. Therefore, we supplied and installed new trace heating and a controller across the entire CHW pipework. Our engineers also carried out electrical testing on the new trace heating cabling.
We then installed new insulation across the complete CHW pipework. The insulation included an aluminium cladding layer and a further Black ProClad coating. Finally, we added new identification labels to the finished insulation. This provided a clearly protected and identifiable chilled-water installation.
How did we Integrate the New Chiller With the BMS?
The existing SWA and control cabling required adaptation for the new chiller arrangement. IDWe Ltd adapted the cabling to suit the replacement equipment. We then completed electrical testing to BS7671:2018 on the adapted SWA supply cabling.
Our controls engineer at Magpie BMS Services Ltd also worked alongside the ICS manufacturer during final commissioning. Together, they completed the run and fault BMS connections for the new chiller. This allowed the new equipment to integrate with the existing building controls.
Following commissioning, we provided the Hospital with the completed commissioning details and O&M documentation for the new air-cooled chiller. This gave the hospital the information needed to operate and maintain the new system effectively.
What did the Completed Chiller Replacement Deliver?
The project delivered a complete replacement cooling system for the GEA Heart Centre AHU.
The finished installation included:
- 77kW ICS iC538 air-cooled chiller
- 410-litre buffer vessel
- New pump set
- Complete CHW flow and return pipework
- New trace heating and controller
- New pipework insulation and protection
- Adapted electrical and BMS connections
- Full electrical and pressure testing
- Manufacturer and controls commissioning
Most importantly, the hospital received replacement cooling following the failure of its previous chiller. The project also brought mechanical, electrical and controls expertise together under one coordinated installation.
Lastly, Our expert HVAC team completed the works while supporting the requirements of a busy healthcare environment. As well as removing redundant equipment and disposed of it through a licensed refuse and recycling facility.
Why Choose IDWe Ltd for Commercial and Industrial HVAC?
A failed chiller can affect critical building services and create significant operational concerns. For hospitals, facilities managers and property managers, replacement equipment must integrate with existing building systems. We provide integrated HVAC and mechanical and electrical expertise for complex commercial environments.
IDWe Ltd’s experienced engineers can manage chiller replacement, chilled-water pipework, electrical works, BMS controls and commissioning. Furthermore, we understand the importance of working within operational buildings.
Our coordinated approach helps clients manage complex commercial HVAC and industrial HVAC requirements through one experienced contractor. Whether you need an energy-efficient air-cooled chiller, replacement equipment or a complete cooling system upgrade, we can help.
Where Does IDWe Ltd Provide Chiller Installation Services?
We support commercial, industrial, healthcare clients and more across London and the South East.
Our air-cooled chiller installation services cover:
- London
- Kent
- Surrey
- Sussex
- Essex
- Hampshire
We can support commercial building cooling, healthcare facilities and other specialist environments. Our team can also manage packaged process chiller replacement projects where existing equipment has failed or requires upgrading. For Facilities Managers and Property Managers, we provide a coordinated approach covering mechanical, electrical and controls requirements.
Talk to our expert HVAC engineers today on 020 8302 7644.
Related NHS Case Studies
Explore more examples of working within healthcare environments:
Pump and Valves – NHS Case Study
Learn more, please read the NHS pump and valves case study
Building Refurbishment – NHS Case Study
Read our NHS building refurbishment project
AHU Repair – NHS Case Study
Discover more, please read our AHU replacement project
FAQs: What Should you Consider Before Replacing an Air-Cooled Chiller?
When should an air-cooled chiller be replaced?
A chiller may require replacement following equipment failure, reliability issues or obsolete components. However, each project requires an assessment of the existing system and operating requirements.
Why choose an air-cooled chiller?
Air-cooled chillers reject heat through ambient air rather than using a cooling tower. This can simplify installation and reduce maintenance requirements associated with cooling towers. They can provide a practical solution where space, water consumption or site requirements influence equipment selection.
What does an air-cooled chiller installation involve?
A complete installation can include chiller removal, lifting, pipework, electrical connections, controls and commissioning. It may also require insulation, trace heating, pressure testing and system balancing.
Which chiller did IDWe Ltd install at Darent Valley Hospital?
IDWe Ltd installed an ICS iC538 77kW packaged air-cooled i-Chiller. The system included a pump set and 410-litre buffer vessel.
Can an air-cooled chiller replace an existing chiller?
Yes, depending on the building’s cooling requirements and existing system configuration. A replacement project should consider capacity, pipework, electrical supplies and controls.
How can a chiller replacement support cooling reliability?
Replacing failed or unsuitable equipment can provide a more appropriate solution for the building’s cooling requirements. However, performance depends on the complete system design, equipment selection and commissioning.
Need an Air-Cooled Chiller Replacement in London?
A failed chiller can create an urgent requirement for reliable replacement cooling. We can manage the complete project from equipment removal through to installation, testing and commissioning. Contact IDWe Ltd to discuss your air-cooled chiller replacement or chilled-water system requirements.
For further details on our HVAC Services and to get a quote, please call 020 8302 7644 or email info@idwe.co.uk
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