Retrofit for water cooled QUANTUM chillers: improving efficiency at the airport
ENGIE Refrigeration is modernising two existing QUANTUM chillers at an airport in Bavaria through a comprehensive retrofit program. The modernisation includes compressor replacement, a new control cabinet, an upgrade of the Siemens PLC and the switch to R-513A refrigerant. This significantly increases energy efficiency without the need for structural alterations to the building or infrastructure.
Industry:
Technical building equipment- Retrofit with R-513A: The conversion replaces the previous refrigerant R-134a with R-513A and brings the refrigeration systems up to a modern, efficient standard – including a new generation of compressors.
- Modernisation under security requirements: Due to the location in the second basement level and strict requirements under the Aviation Security Act, all technicians undergo security checks and receive special training. Installation is carried out exclusively via use of a lift.
Existing refrigeration systems in challenging installation situations place special demands on modernisation projects. At this airport in Bavaria, the customer operates two water cooled QUANTUM chillers. One of the two refrigeration systems had already been successfully modernised by ENGIE Refrigeration – with measurably higher efficiency and significantly reduced electricity consumption. This convinced the operator to have the second chiller retrofitted as well.
For the retrofit, our service team implemented a comprehensive modernisation package: the replacement of the old, oil-free compressors with new QUANTUM compressors, the construction of a new control cabinet, the upgrade of the control system (Siemens PLC) and the adaptation of the piping system, ensure that the refrigeration systems achieve a performance level virtually on a par with new installations. At the same time, the existing tanks remain in place – a significant economic advantage. Furthermore, the existing building management system (BMS) communication had to remain unchanged to avoid regulatory status changes and the associated lengthy approval processes of up to three years.
Retrofit as an efficient alternative to replacing entire chillers
ENGIE Refrigeration solved the challenge of an extremely restricted installation situation: as only Euro pallets can be transported in the basement, installing a new chiller would only have been possible with significant structural alterations. Instead, the retrofit enables a resource-efficient modernisation using efficient technology, without any intervention in the building’s structure . At the same time, the solution meets all safety-related airport requirements and ensures reliable operation.
The project demonstrates the effectiveness of retrofit solutions: they extend the service life of existing refrigeration systems, improve their energy efficiency and offer operators in complex infrastructures – such as airports, hospitals, industrial buildings or data centers – an economical and sustainable alternative to completely replacing the machinery. ENGIE Refrigeration thus creates retrofit concepts that optimally combine efficiency, operational reliability and modernisation in challenging building environments.
Further references
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