Heating Storage Calorifiers Swap out Project for a major FM contractor
Heatxforce were approached by a major FM contractor to deliver a full turnkey replacement of the failing calorifier system.
What was the Problem?
The existing hot water storage calorifier system at a high-demand client facility had reached the end of its service life. Persistent internal wear had led to frequent leaks, resulting in multiple emergency repairs and repeated disruption to the hot water supply. This not only posed serious risks to compliance standards—such as Legionella control and health & safety regulations—but also loss of client confidence due to the operational interruptions.
Originally brought in to carry out repairs, Heatxforce identified that a full mechanical and electrical (M&E) replacement was the only viable long-term solution.
How Heatxforce Helped?
Heatxforce, the specialist Mechanical & Electrical division of The Force Group was appointed by a major FM contractor to deliver a full turnkey replacement of the failing calorifier system.
Our engineers conducted a detailed engineering analysis to correctly assess hot water demand and system requirements. This included:
- Reviewing historical hot water usage data
- Counting demand units (e.g., showers, washbasins, kitchens)
- Calculating peak simultaneous demand
- Applying diversity factors and safety margins
- Considering reheat times and available primary heating circuit temperatures
Using these insights, Heatxforce specified and installed appropriately sized calorifier tanks with large internal heating coils to meet both current and future capacity requirements.
Scope of Works
Mechanical Works:
- Full strip-out and removal of existing large cylindrical calorifier vessels
- Removal of all interconnecting valves and pipework
- Installation of sectional replacement tanks with internal heating coils
- Reconfiguration of pipework and installation of temperature control and isolation valves
Electrical Works:
- Isolation and removal of outdated control wiring
- Installation of new control panels and temperature sensors
- BMS integration and NICEIC-certified testing
Delivery Constraints and Strategy:
To minimise disruption to building operations, the installation was carried out entirely outside of normal working hours. This included evenings and weekends, avoiding noise and interference for the staff present in the building. Careful planning and site coordination allowed for efficient shift work and compliance with health and safety.
Commissioning and Handover:
Following installation, the new system was:
- Fully set up and balanced
- Pressure-tested and flushed
- Commissioned and checked for temperature performance
- Integrated with building controls and left fully operational
- Handover included documentation and client demonstration
Project Summary:
This was a fully managed, turnkey solution delivered by The Force Group, engaging our full range of mechanical, electrical, and project management expertise. From initial load calculations to final commissioning, our team ensured a smooth and effective upgrade with minimal disruption.
Benefits of a Heating Storage Calorifier Swap Out
- Improved Reliability: The new system eliminates frequent leaks and unscheduled downtime, restoring confidence in the building’s hot water infrastructure.
- Compliance Assurance: Upgraded components reduce the risk of Legionella and other compliance-related issues.
- Energy Efficiency: Properly sized calorifiers with high-performance internal coils improve energy efficiency and reduce operating costs.
- Futureproofing: The system was designed with additional capacity and flexibility to accommodate future demand.
- Minimal Disruption: Out-of-hours delivery ensured that building operations continued uninterrupted throughout the project.
- Turnkey Solution: Heatxforce handled everything from design to commissioning, delivering a seamless and professionally managed upgrade.
Heatxforce are here to help
If you’re looking for a new or replacement Heating Storage Calorifiers, we would be very happy to discuss your project in detail. Please call our team on 0121 740 0130 or email us at info@heatxforce.co.uk
From the moment you contact Heatxforce, you benefit from industry leading expertise in Heat Transfer Packages and Fabrication. Heatxforce are part of the Force Group of Companies, which also includes Valveforce, Controlsforce, and Pumpforce.
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Codes, Standards & Certifications
Heatxforce build pressure equipment in accordance with PD5500 and ASME VIII Pressure vessel codes whilst conforming to the European Pressure Equipment Directive (PED) and UKCA Pressure Equipment Safety Regulations (PESR), which are mandatory inspection requirements applicable to pressure vessels and systems.
Our welding procedures are in accordance with ISO 15614-1 and ASME IX.
Welder qualifications are in accordance with ISO 9606-1 and ASME IX.
All of our welding related qualifications are certified by TUV Nord.
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