Future-Proofing a Hospital Chiller System with a Digital Pressurisation Unit
The Challenge
During a routine service visit, Dura Pump engineers identified serious issues with an ageing pressurisation unit and vessel serving a hospital chiller system.
On inspection our engineers found that the vessel was full of water, indicating that the internal bladder had ruptured. The existing pressurisation unit was also found to be very old, corroded and leaking internally, creating a risk of ongoing system pressure issues, reduced reliability and further deterioration.
A second pressurisation unit on site was also assessed and found to be in poor condition. Although the vessel was drained, checked and topped up to the correct pressure, the unit itself had suffered from corrosion, with the casing rotting and leaking.
For a critical hospital environment, these issues presented several risks:
- Unreliable system pressure on the chiller system
- Potential interruption to heating, cooling or temperature-critical services
- Increased maintenance callouts due to ageing equipment
- Leaks caused by corrosion and worn components
- Poor energy efficiency compared with modern equipment.
The Solution
Dura Pump recommended a replacement of the outdated pressurisation equipment with a modern more efficient, fully digital, future-proof pressurisation solution, suitable for the hospital’s chiller system.
The remedial works included the safe isolation and removal of the existing pressurisation unit, followed by the supply and installation of a Flamco Flexfiller 230V pressurisation set. This modern digital unit was selected to provide improved control, reliability and efficiency.
Dura Pump engineers also carried out the required pipework modifications, mechanical connections and electrical connections before testing and commissioning the new system.
Alongside the pressurisation unit replacement, engineers safely isolated, drained down and removed the existing 60-litre vessel. A new replacement vessel was then supplied and installed, mechanically connected, charged and set to the correct operating pressure.
The Outcome
The hospital client now has a modern, fully digital pressurisation solution in place, designed to support the ongoing performance and resilience of the chiller system.
By replacing the ageing and corroded equipment, the hospital reduced the risk of leaks, pressure loss and unplanned disruption. The new pressurisation unit and vessel provides a more reliable, energy-efficient and future-proof solution for a critical building system.
Key benefits included:
- Improved reliability of the chiller system
- Reduced risk of leaks and pressure-related failures
- Replacement of obsolete, corroded equipment
- Better system control through a modern digital pressurisation unit
- Improved energy efficiency
- Fully tested and commissioned equipment
- Greater confidence in the long-term performance of a critical hospital service.
For the hospital, this project helped move an ageing system away from a reactive maintenance risk and towards a more dependable, efficient and future-ready solution.
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