Modernization of existing systems

Modernization or expansion of existing systems

The systems we propose can be implemented in stages, expanded during their operation or modernized, e.g. by changing the type or location of the internal unit.

This issue should also be prepared for and analyzed if possible at the design or concept stage.

This is important because it may turn out, for example, that the existing installation connections are inadequate for the proposed change or expansion and then it would be necessary to perform a new installation, renovate part of the building, etc., which can be a real challenge in an existing or newly commissioned building, not to mention very high investment outlays and considerable difficulties for people working in the facility. We have seen such cases many times.

It is not always possible to predict everything at the concept or design stage, but when we are already at the stage of implementation, we often know more and it is worth considering for a while how we can make the most of what we have at our disposal.

Knowing, for example, the heat and cooling balance of the building, we can predict main pipework or collectors to which we will only connect subsequent sections without demolishing the entire building. There are many options, but you have to remember this and think about it at the right time.

An additional issue is knowledge of refrigeration systems and the ability to calculate the transfer of the correct actual cooling / heating power of devices for new rooms / building zones, taking into account existing systems and operating conditions of a given system and all components that affect it, including the length of the installation, oversizing of the system, internal temperature, external temperature, etc.

Unfortunately, we often see installation companies connecting devices to the existing system without any verification and analysis and then it turns out that the new devices do not achieve the required cooling power calculated by the designer, and the existing ones have much lower efficiency than before.

Sometimes there were situations when the cooling power transferred by the devices was 2 x too small in the end and the investor was surprised that he could not obtain the appropriate temperature parameter in the newly modernized installation.

Additionally, it often turns out that the amount of refrigerant is also not properly calculated and adjusted to the new situation, and this has a very large impact on the operation of the entire system, including its efficiency and service life. Often, the cause of compressor damage is the incorrect amount of refrigerant in the system and its chemical composition, and these are elements that installation companies very rarely verify. This is influenced by a number of factors. The installation company may not have the appropriate knowledge or experience and often also wants to save time, and such analyses require verification and calculations, which translates into much greater involvement, often of different departments of a given installation or design company.

Replacing the system with a new one with the option of modernizing the existing system

If there is only such a possibility, we always consider what options we have when modernizing a given worn-out system, consisting in replacing its components such as aggregates, internal units or parts of the installation.

The standard approach of installation or design companies is to replace the system 1 to 1. That is, we replace the system with the same one as before with all its advantages and disadvantages. This is the simplest solution, but we have to ask ourselves whether it is really the best?

We have already encountered many situations where the system was poorly designed for the needs of the building, i.e. it did not meet the needs of the building in terms of user comfort or was characterized by very high energy consumption or excessive load, which made the service life of the system definitely too short, etc., etc.

If we do not find the cause of the situation, the problem will remain and make itself felt sooner or later. We should always analyze what we can do at the stage of replacing the system with a new one to improve the version of the existing system.

Our company has already completed several replacements of large systems with the modernization of the existing installation, which translated into tangible benefits for investors

Below we present examples of system replacements carried out by ART-KLIMA, along with the modernization of the existing installation

We approach each such implementation individually and estimate what the possibilities are and present various options and solutions so that the investor has a wide range of options to choose from and makes the right decision based on full knowledge.

We manage to end each of our implementations with references.

If you are interested in cooperation with our company, we can meet at the selected facility and discuss various options for replacing or modernizing the system that is in your facility.

Example 1. Replacing the VRF - R22 system with a new system - Investment in Warsaw.

Replacement of the VRF - R22 system with a new VRF - R410A while maintaining the existing installation.

The subject of the investment was the replacement of the old system operating on the R22 refrigerant with a new system operating on the R410A refrigerant.  The external and internal units were replaced, while the existing refrigeration installation was preserved. The replacement was carried out using the entire procedure of verifying the refrigeration diameters and adapting the entire system to work with the new system operating on a different refrigerant.

The R22 refrigerant has different chemical properties than the R410A refrigerant and, additionally, it is characterized by different working pressures and cooperates with a different oil lubricating the compressor system. In other words, these factors are compatible with it and, as a result, the diameters of the pipelines are different and the pressure in the installation is also different. In order to meet these challenges, we had to perform a number of verification activities according to the so-called RENEWAL procedure consisting in replacing the system developed by Panasonic

In addition, we had to remove all the old oil from the installation and get rid of dirt and contamination, we used a special machine for flushing refrigeration systems with a refrigerant without introducing chemicals into the refrigeration system. The effect of these actions was to obtain operating conditions as for a new installation without the risk of losing the warranty.

Example 2. Replacement of GHP systems with new systems - Investment in Ruście near Nadarzyn.

Replacement of GHP systems - gas heat pumps previously operating as single units with common Multi refrigeration systems of the new generation of GHP systems and hybrid systems. The subject of the investment was the replacement of old worn-out GHP units with new ones, but with some modification and modernization of the existing refrigeration installation in such a way as to reduce gas consumption, increase the safety of the system operation, reduce service costs and extend the life of the entire system.

Due to the fact that we only replaced external units and the internal units and the entire installation in the building did not change, the investment costs of the new system were significantly lower compared to replacing the entire system with a new one.

Additionally, we had to remove all the old oil from the installation and get rid of dirt and contamination, we used a special machine for rinsing refrigeration systems with a refrigerant without introducing chemicals into the refrigeration system. The effect of these actions was to obtain operating conditions as for a new installation without the risk of losing the warranty.

Example 3. Replacing the GHP system with a new system - Investment in Rybnik.

Replacement of the GHP system - a gas heat pump previously operating as a single unit in a year-round heating and cooling system with a new hybrid system consisting of a gas heat pump and an electric heat pump operating on a common existing refrigeration system additionally supported by photovoltaics.

An additional drawback of this system was the fact that the building contained a staff apartment, which on the one hand constituted a small share of the entire system's power, but on the other hand was a constant burden for the existing system and forced the unit to operate continuously and a very large number of system operating hours. The natural consequence was much faster system wear.

The subject of the investment was the replacement of the old worn-out GHP unit with a new hybrid system providing significant benefits described below

We only replaced the external unit, and the internal units and the entire installation in the building did not change, the investment costs of the new system were significantly lower compared to replacing the entire system with a new one.

In addition, we had to remove all the old oil from the installation and get rid of dirt and impurities, we used a special machine for flushing refrigeration systems with a refrigerant without introducing chemicals into the refrigeration system. The result of these actions was to obtain operating conditions similar to those for a new installation without the risk of losing the warranty.