Stratford Hospital Chiller Replacement Project

Project Overview: Enhancing Reliability at Stratford Hospital

Working in partnership with ABI, IRS was appointed to replace an existing air-cooled chiller serving a vital theatre air handling unit (AHU) at Stratford Hospital. The hospital’s existing system operated as part of a run/standby configuration, meaning it was essential that one chiller remained operational throughout the works. The project, therefore, required detailed planning to ensure continuity of service while upgrading the equipment to a more sustainable and reliable solution.

The Challenge: Minimising Downtime During Essential Chiller Replacement

The original chiller had been suffering from ongoing reliability and control issues, particularly when the system switched between chillers. These changeovers occasionally caused flow faults, risking interruptions to critical hospital operations.

Our challenge was threefold:

• Keep the AHU operational with only one chiller for as short a time as possible.
• Overcome restricted access due to the main hospital car park layout.
• Deliver a seamless switchover without any system alarms or disruption to the hospital environment.

Given the sensitive nature of the site and its operational requirements, the project demanded careful planning, coordination, and technical precision.

The Solution: Precision Planning and Low-GWP Technology

Following a thorough review of the existing system, IRS selected an Airedale low-GWP chiller to provide a modern, efficient replacement in line with the NHS’s ongoing sustainability and carbon reduction commitments.

To achieve a smooth installation, IRS:

• Worked closely with the BMS provider to update and fine-tune the control software, ensuring smooth changeover between chillers.
• Implemented a temporary traffic diversion to safely manage crane access within the main car park area.
• Planned the lift and replacement between 5:30 and 7:30am on a Sunday morning, avoiding disruption to hospital staff and visitors.
• Conducted detailed pre-lift meetings with all contractors and hospital representatives to ensure everyone was aligned on safety and timings.

This structured approach resulted in a flawless installation, completed safely and efficiently within the tight timeframe.

Project Details

• Client: ABI
• End User: Stratford Hospital, South Warwickshire NHS Foundation Trust
• System Type: Air-cooled chiller replacement serving a theatre AHU
• Manufacturer: Airedale
• Refrigerant: Low Global Warming Potential (GWP)
• Special Considerations: BMS control upgrades, restricted access, time-sensitive crane operation

Collaboration in Action: BMS Integration & Software Enhancement

A key part of the project’s success was the proactive partnership between us and the building management system (BMS) team. Together, we developed and implemented control software changes that allowed the chillers to transfer seamlessly during operation, a significant improvement over the old system.

This collaboration not only resolved the previous flow issues but also enhanced the overall performance and reliability of the cooling plant, giving the Estates team improved control and confidence in the system’s operation.

Overcoming Site Challenges with Careful Planning

The hospital’s main car park created a logistical challenge for the crane lift. To ensure safety and minimise inconvenience:

• We implemented a temporary diversion route, clearly signposted for vehicles and pedestrians.
• The lift was scheduled during quiet hours on a Sunday morning, ensuring minimal disruption to hospital operations.
• On-site teams maintained constant communication throughout the operation, ensuring everything ran to plan.

This level of organisation and foresight is central to IRS’s project delivery ethos, ensuring that every task is executed safely, efficiently, and with minimal impact on client operations.

Client Feedback: Seamless Delivery and Teamwork

“Thanks to you, and all involved to make today seamless! Great teamwork, born from early proactive communication and all helping to deliver and support the lift and shift process.”
– Andy Hall, ABI

“Once again, a quality service, thank you.”
– Mark Wise, Head of Estates (Operational), South Warwickshire Foundation Trust Clinical Services Ltd

This positive feedback reflects the teamwork, attention to detail, and high standards that IRS consistently delivers across all projects.

Results: Reliable Cooling for Critical Healthcare Operations

The successful completion of the Stratford Hospital project means the theatre AHU now benefits from a modern, efficient, and environmentally responsible chiller system. With enhanced controls and reliable performance, the hospital can depend on:

• Improved operational resilience
• Enhanced energy efficiency
• Reduced environmental impact
• Optimised BMS integration

Through this project, we have once again demonstrated our ability to deliver technical excellence and operational assurance in a live healthcare environment.

Why Choose IRS for Healthcare Cooling Projects?

With extensive experience delivering specialist HVAC and refrigeration projects across the UK healthcare sector, IRS understands the unique operational, safety, and compliance challenges of working in clinical environments.

Our services include:

• Full design and build of cooling and refrigeration systems
• Low-GWP and sustainable refrigerant solutions
• BMS control integration and optimisation
• Time-critical project delivery and coordination
• Ongoing maintenance and technical support

Learn more about our Healthcare HVAC Projects here.

Another Seamless HVAC Project by IRS

The Stratford Hospital Chiller Replacement Project highlights IRS’s commitment to technical precision, proactive planning, and teamwork. By collaborating closely with ABI, the BMS provider, and hospital management, IRS ensured a smooth, safe, and efficient installation that enhanced both performance and sustainability.