Martin Hayward, Daikin UK Applied Systems manager, says chiller equipment should be replaced in line with the demands of the building and warns plant managers against simply replacing units like-for-like.
THE expected design life of a building is approximately 60 years, within which time the hvac services may need to be replaced on average four times.

More often than not however, when a chiller needs to be replaced, plant managers specify a like-for-like replacement, assuming that it will not only save them time and money during the specification and installation process, but also in the belief that it is the most suitable for the business operation.

As a result, many businesses may be losing out on some key cost and energy savings, particularly when we consider the variety of 'A' class efficiency-rated chillers available within the marketplace and from Daikin UK.

Surprisingly, in the home environment, if your TV broke down you wouldn't purchase exactly the same TV without considering the other options and looking at the various product developments of the past few years.

However, for some reason in the commercial sector, this approach does not win through and numerous plant managers are simply purchasing equipment on the basis that it has worked until now. However the ultimate factor driving the decision must surely be whole life costs and impending legislative changes.

When we consider the current climate, with high energy price rises and environmental issues at the cornerstone of Government policy, businesses can no longer make decisions based upon like-for-like replacement or simply the outlay cost, as this is no longer a profitable approach.

Whilst purchase cost will remain a key factor in the buying process for many, in order to reap the greatest benefits and unlock the real value from equipment the whole life cost approach should be considered.

Ideally, most plant managers within the process industry will already operate maintenance logs where all details of the chiller and other process equipment are recorded on a regular basis.

Through an analysis of this information, businesses are able to calculate the life cycle costs of existing equipment and then use this information to compare and contrast against future models.

Advisably, a chiller should be checked four times a year with three minor and one major maintenance visit, with inspections addressing water flow, refrigerant charge, alarm history etc.

The major visit would also include compressor oil analysis and cleaning the air-cooled coil which will not only increase the life of the unit but also return the running cost back to the original specification.
In the long term, the monitoring process should be a top priority and in some cases can help in preventative maintenance measures.

Following the calculation of the whole life cost of equipment, knowledge gained from maintenance logs will add further credibility to a cost proposal and ensure that maintenance costs and even a contingency budget can be planned into the proposal.

Market conditions
A further factor influencing the decision-making process, particularly for those considering repairing equipment rather than replacement, is government legislation and planning issues.

Regulatory pressures in the form of the Montreal Protocol and the phase-out of R22 refrigerants is of crucial importance for plant managers. Introduced by the European Union, the Montreal Protocol enforces the removal and replacement of R22 by 2015.

For end users, an understanding of current market conditions is crucial during the replacement and specification process. At the end of 2009 it will be illegal to use virgin R22 for maintenance and servicing, with a ban on all HCFCs by 2015, including those that have been reclaimed and recycled. In the meantime the cost of R22 is expected to rise as stock diminishes throughout the market place and will therefore lead to increased costs for those still operating equipment.

For end users still operating with R22 now is the time to act, but the costs of doing so must be considered as part of a whole life cost approach.

If a business is currently operating chiller equipment on R22 refrigerant and the system requires some large maintenance works, end users and more specifically the plant manager, must weigh up the benefits of a complete refurbishment or the replacement of chiller equipment.

It is here that the installer and specifier can offer advice and support to customers on replacement.

Designed for purpose
The Daikin Applied Systems team work together with end users to design chiller systems to meet the individual needs of a business. With an understanding of all the key issues and the demands of business operations, the Daikin team is able to build an application proposal.

End users should not only consider the capital cost of equipment but look at the wider issue of whole-life costs, including the long-term impact of the equipment, including the carbon footprint.

The real challenge however must be one of education as well as a change of attitude, ensuring that businesses consider the long term view and replace chiller equipment in line with the demands of the building rather than the short term demands of the back pocket.

www.daikin.co.uk