The replacement of old out-of-date, often inefficient, high maintenance air handling plant can present a major headache for the end user. Here, Paul Smiles, sales director of Weatherite Manufacturing, offers one solution
AIR handling and air conditioning equipment installed around 15-20 years ago is, in many instances, coming to the end of its useful life. The result is creating problems for managers responsible for their operation.

Mechanical and performance deficiencies, frequent breakdowns and spiralling maintenance and repair costs are just some of the issues which are creating a nightmare scenario, for many companies.

Faced with these problems, end users and facilities management companies have to seek effective solutions. At the same time, the economic pressures on businesses are now so acute, managers are understandably reluctant to undertake any work which involves prolonged downtime and disruption while ripping out the old equipment and starting again from scratch.

Thankfully there is an alternative. Substantial savings can be achieved in installation costs, downtime and long term energy usage by replacing old, worn-out equipment, with bespoke replacement packages from Weatherite.

With many off-the-shelf solutions, current equipment may not match the footprint of the existing system or dovetail with existing services. Replacement packaged equipment from Weatherite provides a technologically-advanced solution with all the energy and performance benefits of a new system but with the added advantage that the new equipment will match the existing physical parameters, in terms of footprint, services and ductwork.

Many of the systems still on rooftops are, by definition, based on technology that is decades old. Components, design and energy efficiency standards have made giant strides in that time. A contemporary replacement unit offers all the advantages of substantial - often spectacular - savings in costs and performance.

In Weatherite's case that means systems that have been designed to achieve key performance criteria for the minimum of capital outlay.

Energy efficiency is a key driver in any business today, both in terms of cost reduction and meeting legislative requirements.

There is often pressure on suppliers from clients, to improve energy performance. Weatherite has designed all its systems to feature the latest generation of high efficiency fans to deliver substantial lifetime cost savings. The units also incorporate state-of-the-art components such as variable speed drives; scroll compressor technology; high efficiency motors and web-enabled control systems.

Here again, many rooftop air handling units installed 20 years ago use R22, an HCFC for which the supply of virgin refrigerant for service applications will disappear completely by 2010.

This provides another good reason for the end-user to choose a bespoke solution and a completely new system incorporating an environmentally-acceptable refrigerant.

Take the Marks & Spencer branch in Bath. The existing rooftop air conditioning unit was more than 15 years old, worn out, inefficient and ineffective. However, the existing ductwork was still in good condition and usable.



After undertaking a survey, the existing unit was replaced with a new energy efficient, state-of-the-art, Weatherite unit, built to the exact footprint of the old system.

This meant all existing connections and ductwork could be utilised thereby keeping costs, disruption and downtime to an absolute minimum. The store now has a high performance, energy saving air conditioning system.

At Havering Magistrates Court, the building services and roof were in need of major refurbishment. However normal court procedures had to continue.

Working closely with the roofing contractor, Acclaim Contracts, four air handling units were specifically designed, manufactured and installed into the exact footprint of the old, inefficient plant.

This meant that all existing distribution equipment, including ductwork, gas and water pipes, electrical cabling and other ancillaries were used, thereby keeping costs, disruption and labour time to a minimum while providing the court with the very latest in air handling technology.

At the Royal Victoria Shopping Centre, Royal Tunbridge Wells, the existing air conditioning equipment for this busy shopping centre was provided by a number of remote units, each of which had come to the end of its useful life and needed replacing as a matter of some urgency.

Here, after the survey, Weatherite recommended combining the existing remote units into one rooftop packaged unit which not only provided a major cost saving but also delivered 25% increased duty, latest high efficiency fan technology, remote interrogation of the system and a shorter pay back period.

One of the biggest problems facing facilities managers, when upgrading plant and facilities, is downtime. Having new equipment installed, especially if it involves major structural changes, is inevitably going to cause disruption. The bespoke design of a Weatherite unit greatly reduces the work involved. Installation is also much faster and simpler as the units undergo full testing and pre-commissioning before leaving the factory. The systems are also designed to satisfy the demands of today's fast-track building environments by keeping installation demands to a minimum. And, as the replacement units are designed to fit directly into the footprint of the old unit to be replaced, existing ductwork and services can usually be used, without disruption, saving a time and cost.

The cost-saving and performance benefits of a direct replacement unit do not end once commissioning has taken place. All facilities managers know a good preventative maintenance programme will ensure the optimum performance of the air handling system and, of course, maximise cost-savings.



Weatherite provides a package of services that can last for the lifetime of the unit.

Single source responsibility is becoming very important to clients. They prefer the continuity and cost-efficiency of having one supplier to handle the whole process from the initial site survey through manufacture and commissioning.

Many also want the company to take care of the planned preventative maintenance and emergency cover as well. It's all part of the all-round approach to air-handling available from Weatherite.

Weatherite T: 0121 665 2266