Stanlow 6 (“Blue Building”) accommodates a large number of multi-skilled ESSAR Oil UK engineers and senior managers. The building consists of a large open-plan office area with perimeter cellular offices.
Project Requirement
The property was previously served by 3No. 22-year-old Hitachi VRF systems each operating on R22, a refrigerant that is now banned under F-Gas regulations. In addition, parts for the existing system were obsolete and the plant had reached end of life.
Ventilation to the building was provided by an AHU with a steam heating coil, supplying filtered fresh air and heated supply air via the legacy steam system.
Spectra Energy Group was appointed to design, install and commission a new energy-efficient heat recovery VRF system, to undertake a full deep clean of the existing AHU ventilation ductwork, and to install new control systems and electrical mains power to serve the plant.
Spectra Energy Group Delivery
Spectra acted as main contractor, delivering the project with on-site teams working predominantly out of hours to avoid disruption to ESSAR operations.
Our full design and build scope included:
Design & Engineering
- Initial design survey and full heat-loss assessment
- Identification that the existing legacy systems were undersized in kW dutyfor current occupancy levels
- Detailed design of a replacement VRF system with heat recovery capability
VRF System Installation
- Installation of 3 No. Samsung VRF systems
- Bespoke plant area created for external condensing units, mounted on a Big Foot frame system
- Systems designed to deliver simultaneous heating and cooling
Fan Coil Units
- 10 No. Samsung 360° round-flow cassette unitsserving the open-plan office
- 22 No. Samsung Wind-Free wall-mounted units, one per cellular office
- Each office fitted with a local room controller with ±3°C adjustment from a 21°C setpoint
Central Controls & Energy Management
- Installation of a Samsung central controller with 7-day time clock
- Programming of time schedules and stop signals to prevent unnecessary out-of-hours operation
Electrical Works
- New 1-phase ring mains installed
- New 3-phase electrical supply for external condensing units
- Installation of a new earth bar
- Full NICEIC electrical testing and certification
Ventilation Improvements
- Deep clean of both supply and return AHU ductwork
- Replacement of AHU filters and belts
- Full air re-balance of VCDs and commissioning to ensure correct airflow rates to all areas
Corrosion Protection
- External condensers treated with Bronz-Glow coil protection, safeguarding against NOx and salt-air corrosion due to site environmental conditions
End Result / Client Testimonial
ESSAR Oil UK Ltd received a new low-GWP, energy-efficient Samsung heat recovery VRF system delivering a COP of 4.3, an ROI of under 7 years, and an expected equipment life cycle of 20+ years.
The client also benefits from a 7-year extended manufacturer parts warranty, with Spectra providing the ongoing pre-planned maintenance.
All work was completed out of hours with zero disruption to ESSAR operations. Spectra fulfilled full main-contractor responsibilities, including:
- Access and egress management
- Fire alarm isolations
- Nightly permits for general and hot works
- Leaving the building clean and operational each morning
Project Details
- Category: Electrical
- Location: Stanlow 6 Oil Sites Road Ellesmere Port Cheshire CH65 4BH