Case Study
Compressor Replacement at a College in Gloucestershire
In the summer of 2024, a college in the Gloucester area faced an urgent issue with one of the Bitzer screw compressors in its central chiller system
. The compressor’s windings were down to earth, leading to a complete failure. To ensure the chiller’s operational reliability, a like-for-like replacement was scheduled during the school holidays to avoid disruptions to the college’s academic calendar.
The Challenge
The college’s chiller system had been in operation for several years, ensuring a stable environment across campus buildings. However, the failure of the screw compressor due to faulty windings caused significant issues with the system’s cooling capabilities.
The faulty compressor needed to be replaced immediately to restore the cooling system’s full function. Given the size and weight of the compressor, the project required careful planning, specialised equipment, and skilled personnel to ensure safe and efficient removal and installation. Additionally, the work needed to be carried out with minimal disruption, making the school holidays the ideal window for this project.
The Approach
Key Highlights Of The Solution
- Efficient Project Execution During School Holidays:
The entire compressor replacement was completed within the school holiday period, ensuring no disruption to the college’s daily operations. - Specialised Lift and Shift for Safe Installation:
A specialist lift and shift team safely removed and installed the large, heavy Bitzer screw compressor, ensuring the project was completed smoothly and without complications. - Full System Upgrades with PRV Replacement:
In addition to replacing the compressor, all system pressure relief valves (PRVs) were upgraded, improving the overall safety and longevity of the chiller system.
Step 1: Refrigerant Recovery
Before any physical work could begin, the system’s refrigerant was carefully recovered in compliance with environmental regulations. This ensured safety and prevented any harmful emissions during the replacement process.
Step 2: Disconnecting Electricals
The electrical connections to the faulty compressor were safely disconnected to ensure a hazard-free working environment for the replacement process. Our skilled electricians made sure all circuits were properly de-energized.
Step 3: Removal of the Compressor
Given the significant size and weight of the Bitzer screw compressor, a specialist lift and shift team was engaged to handle the removal. The team used cranes and lifting gear to safely extract the compressor from its housing within the plant room.
Step 4: Installing the New Compressor
Once the old compressor was removed, we installed the like-for-like replacement Bitzer screw compressor. Our team ensured that all pipework, refrigerant lines, and electrical connections were reconnected to the highest standards of safety and efficiency.
Step 5: System Upgrades – PRV Replacement
During the replacement process, it was also important to address other system components to ensure long-term reliability. We replaced all system pressure relief valves (PRVs), which are critical for maintaining the chiller system’s safe operation.
Step 6: Testing and Commissioning
With the new compressor in place and the system fully reassembled, the chiller underwent rigorous testing. All electrical connections were verified, refrigerant was recharged into the system, and the chiller was commissioned back to full operation.
Timeline: The entire process, from refrigerant recovery to testing and commissioning, took 3 days. Thanks to careful planning, the project was completed within the school holiday period, avoiding any disruption to the college’s daily operations.
Project Outcome
The replacement of the Bitzer screw compressor, along with the system PRV upgrades, restored the chiller to full functionality. As a result:
- Improved reliability: The college now benefits from a fully operational chiller system with reduced risk of further breakdowns.
- Minimized disruptions: By carrying out the work during the school holidays, there was no interruption to the college’s regular activities.
- Enhanced system safety: With the new PRVs installed, the system is better equipped to manage pressure and operate safely.
Conclusion
Replacing the Bitzer screw compressor at this Gloucester-based college was a complex yet carefully managed process. From initial diagnosis to completion, our team worked closely with the college to ensure minimal disruption and long-term system reliability. The successful replacement of the compressor, along with the PRV upgrades, now provides the college with improved cooling capacity and operational peace of mind.
”The college's maintenance team was highly satisfied with the speed and efficiency of the replacement process. The minimal downtime and quick turnaround meant the chiller was back up and running before the new term began. The project was delivered on time and within the planned budget, much to the satisfaction of the college’s facilities management.
For businesses in need of top-tier chiller maintenance and parts replacement services
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