Following a site survey it was identified that 16 free cooling coils were fractured and/or swollen from ice build-up and needed replacing on two Airedale chillers for a client in the Midlands.

Both chillers had multiple fractures running top to bottom on the return bends of each free cooling coil, as seen in the photo (below right). Some fractures were small cracks, others were complete splits from the aluminium frame and so it was strongly advised to replace all.

While the coils were separated out from the units, the units were thoroughly washed through ready for the replacement coils.

The team helped set up the crane lift for the replacement coils and to bring down one set of redundant coils for disposal and lift the new coils to the roof, removing the wooden crate packaging once on the roof again for disposal and recycling.

The project, headed up by Head of Operations James Allsop and Operations Manager Darren Samme, was successfully completed over the summer of 2025. Air Conditioning Supervisor Chris Stanyer, alongside Senior Engineers Anthony Dyer and Bryan Marshall and Engineer Jason Macgregor were also allocated to the job to ensure the project ran smoothly and was delivered on time.

• Replaced 16 free cooling coils

• Airedale chillers had cracked and/or fractured return bend pipes

• Crane was needed to lift new pipework and remove old

• Scaffolding was erected around each chiller

• Washed through the DX condenser coils before reinstalling

• Isolated then stripped down each chiller to replace and/or maintain parts

• Recharged each chiller with refrigerant

• Recycled old pipework

The team removed the free cooling coils from both chillers, isolated each chiller by closing the flow and return valves (3-way diverter valve) and drained down the remaining water from the coils.

They then disconnected the framework and fans sited on top of the chiller, disconnected the water pipework from the free coiling coils and removed from the chillers’ framework supporting the DX coils.