Service Overview
- Installation Type: Air-cooled packaged chillers
- Service Area: Nairobi and surrounding areas
- Installation Duration: 1-3 days depending on capacity
- Typical Cost Range: KES 80,000 – 300,000 (labor only, varies by size)
- Best For: Mid-sized commercial buildings, data centers, manufacturing facilities
- Cooling Capacity: Units typically range from 20 to 500 refrigeration tons
- Warranty: Most installations include 1-2 year workmanship guarantee
Air-cooled chillers provide reliable, efficient cooling for Nairobi’s commercial and industrial facilities without requiring cooling tower water systems. These self-contained units reject heat directly to ambient air through integral fans and coil assemblies, making them ideal for locations with water scarcity concerns or limited space for auxiliary equipment. Professional installation ensures optimal performance and longevity.
Pre-Installation Assessment
The installation process begins with thorough engineering evaluation of cooling requirements and site conditions. HVAC engineers calculate the facility’s total cooling load considering building size, occupancy, equipment heat generation, and solar gains. They verify the selected chiller capacity appropriately matches peak demand with suitable safety margins.
Structural engineers assess the installation location, typically rooftops, ground-level equipment pads, or dedicated mechanical areas with adequate outdoor air access. Air-cooled chillers are heavier than equivalent split systems, with weights ranging from 1,000 to 10,000 kilograms depending on capacity. They evaluate structural loading capacity, ensuring roofs or foundations can support equipment weight plus dynamic loads from operation.
The team assesses ambient conditions at the installation site. Air-cooled chiller performance depends significantly on ambient air temperature, with capacity decreasing and power consumption increasing during Nairobi’s warmest periods. They evaluate prevailing wind directions, potential air recirculation issues, and proximity to air intake louvers or windows that might draw in chiller exhaust air.
Electrical infrastructure assessment verifies adequate power capacity for the chiller’s compressors and fans. Air-cooled chillers typically require substantial three-phase electrical supply, often 400V systems drawing hundreds of amperes for larger units. Engineers coordinate with facility electrical systems to plan dedicated circuits, transformers if needed, and appropriate protection devices.
Preparation and Foundation Work
Preparation involves constructing or reinforcing equipment foundations. For ground-level installations, concrete pads are poured with proper dimensions and reinforcement to support the chiller’s weight. The pad includes anchor bolt embedments for securing the unit and is elevated slightly above grade for drainage. For rooftop installations, structural steel support frames are fabricated and installed, distributing weight across roof structural members.
Vibration isolation is incorporated into foundations through isolation pads, spring mounts, or isolation curbs. This prevents vibration transmission through building structures, which is particularly important for rooftop installations where vibration can cause noise complaints in spaces below.
Access routes are prepared and cleared for equipment delivery. Large air-cooled chillers may require crane lifting for rooftop placement or specialized rigging for indoor mechanical room installations. The team coordinates with building management, secures necessary permits, and arranges traffic control if crane operations affect public roads.
Technicians prepare chilled water piping penetrations through roofs or walls, installing sleeves and ensuring proper waterproofing. They plan routing for supply and return chilled water lines, typically large diameter insulated pipes, from the chiller location to connection points in the building’s chilled water distribution system.
Core Installation Process
Installation begins with positioning the air-cooled chiller on its prepared foundation using cranes or forklifts depending on size and location. Technicians ensure precise leveling using precision levels, adjusting support points as needed. The unit is anchored securely to the foundation using anchor bolts and seismic restraints where required by building codes.
Chilled water piping connections are made to the chiller’s evaporator. Technicians install isolation valves, pressure gauges, thermometers, and flow meters for system monitoring and maintenance. Flexible pipe connectors are often installed adjacent to the chiller to accommodate thermal expansion and reduce vibration transmission to building piping. All connections are insulated with closed-cell foam insulation to prevent heat gain and condensation.
Electrical installation connects three-phase power to the chiller’s main disconnect and control panel. Technicians run properly sized conductors through conduits from electrical panels to the equipment location. They install motor protection devices, fused disconnects, and ensure proper grounding according to Kenyan electrical codes. Control wiring connects the chiller to building automation systems if integrated controls are specified.
The refrigerant circuit, which comes factory-charged in most packaged air-cooled chillers, is verified for proper charge and leak-free operation. Technicians check all refrigerant connections, perform leak tests, and verify sight glass indicators show proper refrigerant levels. For field-assembled units, they evacuate moisture from refrigerant circuits and charge with manufacturer-specified refrigerant types and quantities.
Control systems are configured according to facility requirements. Modern air-cooled chillers include sophisticated microprocessor controls managing compressor staging, fan operation, water temperature setpoints, and safety monitoring. Technicians program setpoints, configure alarms, and integrate with building management systems for remote monitoring and control.
Testing and Commissioning
After installation, comprehensive testing verifies system performance and safety. Technicians perform electrical checks including voltage balance, amperage draw at full load, and proper motor rotation. They verify all safety controls function correctly including high/low pressure cutouts, antifreeze protection, and flow switches.
The chiller undergoes startup procedures following manufacturer protocols. Initial operation is monitored closely with technicians observing compressor operation, refrigerant pressures and temperatures, oil levels, and condenser fan operation. They measure entering and leaving chilled water temperatures, calculating actual capacity and comparing to rated specifications.
Performance testing continues over several hours, monitoring system performance as building loads vary. Technicians optimize control settings, adjust water flow rates if necessary, and verify energy efficiency meets expectations. They test all operating modes including staging of multiple compressors if equipped and night setback operation if programmed.
The installation team provides training to facility maintenance staff covering routine operations, filter cleaning schedules, refrigerant monitoring, water treatment requirements, and troubleshooting procedures. They supply comprehensive documentation including electrical schematics, piping diagrams, control sequences, maintenance schedules, and warranty information. Professional air-cooled chiller installation provides Nairobi facilities with reliable, efficient cooling infrastructure supporting critical operations and occupant comfort.
