ESSAR Oil UK – Stanlow 6 Offices VRF AC & Electrical Mains Power Installation

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

ESSAR praised the high standard of installation, improved temperature control across all offices, and the additional engineering consideration provided through coil protection—extending the longevity and reliability of the system. Systems installed to a high standard with the correct office temperatures now been provided for many years ahead, coil protection to the condensing unit providing additional engineering consideration into the equipment and systems life cycle.