Keeping Cool Heads – Chiller Maintenance and Coil Replacement at Cardiff University
How Routine Maintenance Visit Prevented Potential Future Issues
Background
Cardiff University has trusted Cooltherm as its HVAC service and maintenance partner for the past five years under an ongoing maintenance contract.
The Cubric Building, home to cutting-edge brain imaging facilities, relies on precise environmental control to ensure the integrity of sensitive equipment and the comfort of its occupants.
During a scheduled maintenance visit to the Cubric Building, Cooltherm’s expert engineers detected lower refrigerant levels in several circuits of the building’s key chiller. Refrigerant leaks can quickly escalate, compromising system performance, increasing energy costs, and risking equipment failure.
Action
Cooltherm acted quickly, providing a full assessment and presenting options to the University.
Rather than a short-term fix, the University chose a proactive approach: replacing a total of 12 condenser coils to reinforce system integrity and future-proof the chiller’s performance.
The chiller was fully drained of remaining refrigerant into clean cylinders, enabling an exact calculation of refrigerant loss.
All 12 condenser coils (6 left-hand, 6 right-hand) were in stock and deployed to site immediately, minimising downtime.
A thorough leak test using inert nitrogen was conducted, confirming that all new coils were fully sealed.
The system was then recharged with the recovered refrigerant and supplemented with virgin refrigerant to restore optimal levels.
Results
The entire process, from the initial detection of the refrigerant leak through to the recommissioning of the fully operational chiller, was completed within just five days.
This rapid response meant that the CUBRIC Building’s critical cooling infrastructure was restored to full capacity swiftly, minimising downtime and maintaining optimal conditions.
By choosing to replace all 12 condenser coils rather than addressing individual leaks, Cardiff University have maximised the long-term reliability and efficiency of the chiller, significantly reducing the risk of future leaks and the associated operational disruptions.
Because of Cooltherm’s forward planning and immediate access to replacement components, disruption to the building was kept to an absolute minimum. The availability of in-stock parts, combined with the swift and coordinated work of Cooltherm’s experienced engineers, led to an uninterrupted workflow from beginning to end – reinforcing the value of having a reliable service partner in place for critical HVAC systems.
Without a robust Service & Maintenance contract in place, the leak in this particular chiller could have gone unresolved for much longer. Not only was the issue spotted during scheduled maintenance, but having a signed contract meant Cooltherm were able to prioritise and deliver a rapid resolution.
Through expert maintenance, fast response, and transparent advice, Cooltherm helps organisations like Cardiff University protect their HVAC investments, maintain critical operations, and plan proactively for long-term efficiency and reliability.