Project Overview

Project Overview: In a recent project, our team was tasked with supporting a prominent high-street clothing retailer in the removal and replacement of a vital 5-tonne chiller unit, enabling critical roof repairs on their listed building. The project required precision planning and execution to minimise disruption to the retailer’s operations and nearby public areas, all while ensuring the building’s cooling system remained operational post-installation. Client Challenge: The client, a well-known clothing retailer, required immediate roof repairs, but a large 5-tonne chiller obstructed access to the roof. To facilitate these essential repairs, the existing chiller had to be removed and, after repairs were completed, replaced with a newly designed and rerouted chilled water pipework system that could accommodate the new unit. This involved: Removal of the old chiller. Roof repairs. Rerouting and redesigning chilled water pipework. Installing a new chiller. All work needed to be done with minimal disruption to the retail store’s operations and local traffic in a busy city centre. Our Approach: Planning and Permits: We conducted a comprehensive site assessment to determine the safest and most efficient method for removing the existing chiller and rerouting the chilled water pipework. Due to the store’s central location, the project required extensive coordination with local authorities to secure permits for road closures, as a crane would need to be deployed to lift both the old and new chillers. Crane Operation and Timing: With the busy nature of the surrounding streets, the removal of the chiller was scheduled for a Sunday to minimise public disruption. This meant carefully planning logistics with the crane operator and securing road closure permits for the operation. Picture 1: Shows the roof plant area before work commenced, highlighting the logistical challenge of working within a constrained and busy environment. Picture 2: Captures the moment the original chiller was safely hoisted from the roof using a crane, requiring the full closure of nearby roads. Redesigning Pipework and Roof Repairs: During the roof repair phase, we simultaneously redesigned and rerouted the chilled water pipework to ensure compatibility with the new chiller. The new design allowed for easier maintenance and greater efficiency for the building’s cooling system, a key improvement for the client. Installing the New Chiller: A few weeks after the roof repairs and pipework rerouting were complete, we repeated the crane operation process. Again, the necessary road closures were carefully coordinated, and the new chiller was lifted into position without incident. Final Commissioning: After the successful installation of the new chiller, our engineers finalised the project by commissioning the new system, ensuring it was fully operational and ready for handover to the client. Picture 4: Showcases the completed installation, with the new chiller now in place and fully connected to the redesigned pipework, ready for commissioning. Results: Zero Operational Disruption: By executing key tasks on Sundays and securing the necessary permits for road closures, we minimised disruption to both the store’s operations and the surrounding public areas. Improved System Efficiency: The new chiller and re-routed pipework provide