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When a longstanding client’s central chiller reached the end of its service life, they needed more than a like-for-like replacement. The brief called for a modern, highly energy-efficient chiller that not only could handle current cooling loads but also easily scale up for future growth. Working within strict budget constraints, Refcool delivered a cutting-edge 108 kW modular chiller system – notably the first of its kind to be installed in the UK – along with a full turnkey installation including new pumps, electrical works, and insulation.
The client’s existing large central chiller was failing and inefficient, jeopardizing the facility’s cooling reliability. Replacing it posed several challenges: budget limitations, the need for minimal downtime during swap-out, and a requirement for forward-looking capacity. The client wanted a solution “ready for the future,” meaning the new chiller should be easily upgradable or expandable to higher capacity if needed later. Additionally, the project involved more than just the chiller swap – the scope included replacing aging pumps and integrating the new system with existing infrastructure (including a recirculation pump skid), as well as safe removal of the old unit which was mounted on an elevated outdoor platform. All of this had to be achieved while maintaining continuity of cooling to critical operations.
Refcool’s answer was a state-of-the-art modular chiller installation executed as a turnkey project. After assessing the site, our team handled everything from decommissioning the old chiller and coordinating a crane lift to remove it, to installing the new chiller with all necessary ancillary equipment. The chosen unit was a nominal 108 kW air-cooled chiller, the first of its model in the UK, featuring twin high-efficiency scroll compressors for staged cooling capacity. The chiller came equipped with inverter-driven fans and microchannel aluminum condenser coils, which together enhance performance and reduce energy consumption. In addition, space-saving design elements like a fully hinged control cabinet make maintenance easier – a thoughtful feature of this advanced chiller model.
To address future capacity needs, the modular nature of the chiller allows additional units or upgrades to be integrated with minimal hassle, effectively future-proofing the cooling system. Alongside the chiller, Refcool supplied a new recirculation pump skid with redundant pumps, and upgraded the pipework and insulation for the large-diameter connections, ensuring optimal flow and minimal thermal losses. All electrical wiring and controls integration were handled by Refcool’s technicians, providing a single-point solution for the client. Once installation was complete, our engineers commissioned the system and verified performance. We also managed the environmentally responsible disposal of the old chiller unit, including refrigerant recovery, as part of the contract.
The project was completed on time and within budget, restoring confidence in the facility’s cooling capabilities. The new 108 kW modular chiller immediately delivered improved efficiency, resulting in noticeably lower energy consumption for the same cooling output. Thanks to features like electronic expansion valves, inverter fans, and multiple scroll compressors, the system optimizes its performance especially at partial loads – which is where the facility operates most of the time – leading to significant energy savings. The client also gained peace of mind knowing the chiller can be easily expanded or enhanced as their cooling demand grows, without needing another full replacement. The turnkey installation meant minimal disruption: the old unit was lifted out and the new one in place seamlessly, with all piping, electrical, and insulation work expertly handled by Refcool. By decommissioning and removing the outdated chiller, Refcool cleared a potential environmental and safety hazard, further benefiting the client.
In summary, Refcool’s innovative solution not only solved the immediate challenge of a failing central chiller but also provided the client with a future-ready cooling infrastructure. The UK-first modular chiller serves as a showcase of modern HVAC technology, combining efficiency and smart design. This successful upgrade demonstrates Refcool’s ability to meet strict client requirements – including cost and expansion potential – while delivering a persuasive ROI through energy savings and reliability.
