Case Study: Air-to-water Chiller Installation at The London Coliseum
Replacement of chiller unit on theatre’s roof space
At Cooper Weston Group, we recently completed the installation of a new Keyter air-to-water chiller unit on the roof space of The London Coliseum, a multi-arts venue and the largest theatre in London’s West End.
The new, more eco-friendly chiller supplies chilled water to the building’s existing air handling units (AHUs), providing cool air to various areas of the building, including the 2,359-seat theatre.
This project, part of our mechanical and electrical installation services across London and the South, involved assessing the needs of a large commercial venue, removing the existing unit, using a 300-tonne crane, and closing a road.
Contact us to discuss your mechanical and electrical needs, whether your equipment requires replacement, maintenance, or repair. Our NICEIC-approved electricians and gas-safe engineers are highly skilled and experienced, and we always deliver an excellent service to our clients.
Project overview
We worked with The London Coliseum to replace its existing Daikin chiller unit, which was installed on the roof. We proposed its removal and the installation of a Keyter air-to-water chiller unit, which has a low GWP refrigerant R454B (467GWP) compared to the previous chiller, with silent rings on the fans to reduce noise.
Throughout this process, it was important to consider flow rates and pressure losses for the new unit and the chiller mount locations, which needed to be altered as the new chiller was narrower. To allow for removal and installation, we organised a road closure and the use of a 300-tonne crane at a time convenient to the theatre’s schedule.
Works Completed:
New chiller specs:
- Low GWP refrigerant R454B (467GWP)
- Silent rings on the fans
- ABB switchgear
- 400A Three-phase without neutral
- 3 circuits and 2 scroll compressors per circuit, providing a great part load
efficiency and resilience if a circuit were to fail - 12-month warranty as standard from commissioning
In addition, the pipework and panel orientation closely matched the existing unit with the pipework on the left side of the unit, aiding installation.
We gained access to the theatre’s roof space to remove the existing Daikin chiller unit and installed a new Keyter air-to-water chiller unit, which supplies chilled water to the building’s existing AHUs.
- We replaced the old Grundfos D80-120 F twin-head pump with a suitable twin-head inverter-driven pump capable of 25l/s 70kPa to meet the new chiller’s required flow rate and pressure losses.
- As the new chiller is narrower than the existing one, and would only catch the existing steels by approx. 62mm on either side, we allowed for new steels and plates to be supplied and installed on top of the existing steels to line up with the new chiller AV mount locations.
- All new 150mm pipework was completed using carbon steel welded tube, butt welded fittings and PN16 flanges fabricated off-site. All valves were manufactured by Crane.
- We advised on and replaced the existing pressurisation unit (PU), which was a budget model, with a more commercial unit. We also installed a GRP cabinet to house the new unit for weather protection and a larger 50-litre storage tank to serve it.
Despite encountering unexpected gas works along St Martins Lane, we found a solution to ensure the project was completed on time and within budget. We coordinated with structural engineers and the gas works company to devise a solution which allowed the crane to proceed smoothly and ensured a seamless exit from the site.
To complete this removal and installation, we worked alongside Southern Cranes and Access, using a 300-tonne crane. We closed the road from 6 a.m. to 5 p.m. During this time, we removed the old chiller from the roof, this was taken away by a HIAB. The supplier of the new Keyter unit recycled the old components again contributing to the eco-friendly aspect of the project. They then lifted the new chiller and all associated decking, steels, pipework, pumps, and other ancillaries to the roof.
To help reduce costs we utilised the existing 400A supply and installed a new 400A three-phase isolator to help with safe isolation when working on and maintaining the machine.
Conclusion
Our team successfully completed this M&E installation on time and within budget for our client. Our work from the initial proposal to completion has ensured they have a new chiller that’s more eco-friendly and suitable for the existing AHUs in the theatre, helping to maintain a comfortable climate for staff and theatregoers.
Get in touch
At Cooper Weston Group, we have decades of experience as fully qualified M&E contractors working with commercial properties. Our team can effectively manage your mechanical and electrical installations, including replacements and ongoing maintenance. Speak to us today on 0800 669 6229 or [email protected] to discuss your requirements.
