Maintenance

We provide a variety of solutions from basic periodic plant inspection through to Starcare – a professional PPM programme incorporating both scheduled maintenance tasks and fully documented record keeping to satisfy statutory and business requirements.

Our infrastructure incorporates a nationwide network of 9 branch offices fully staffed with experienced management teams and a team of more than 80 mobile field engineers to support your business.

Northern Ireland and Eire are supported by our independent, locally based partners. This professional local support is complemented by our complete range of services.

Each branch is managed by an experienced industry professional and supported locally by a multi-disciplined team comprised of sales, technical, and administration personnel. Business support systems are standardised throughout the company and deploy the latest technology.

Our team of mobile field engineers can provide you with a range of strengths and experience. We invest in continual engineer development and, as a minimum, all are in possession of:

  • CSCS Skillcard
  • ACRIB Safe Handling of Refrigerants (DTB, F-Gas & Ammonia)
  • Safety Passport - CCNSG
  • CITB Essential Electrics
  • First Aid
  • Manual Handling

Any of these local resources can be rapidly supported from any of our other locations.

Contact

Willie Little

Key Accounts Manager - Maintenance

Related Case Studies

  • AGC Chemicals Europe


    Based in Thornton Cleveleys, AGC Chemicals Europe is a global leading producer of fluorochemicals used in industrial applications, agriculture, construction and much more.
    When the site was hit by a major failure of  one of their process heat exchangers, an onsite contractor recommended Star as the reliable experts for the job.

    The equipment failure meant that AGC Chemicals could not operate its refrigerant process line. The process fluid needed to be cooled to below -300C which required specialist Low Temperature (LT) refrigeration equipment. Downtime on this process line is extremely costly to the business if it is not operational, so it was essential that an assessment and plan of action was developed rapidly in order to deliver the right solution. The client was looking for a temporary refrigeration solution for their process line that would allow them to  be operational again as quickly as possible.

    A team of senior engineers from Star’s local branch attended site within half an hour of the call-out. The issues were established and the temporary solution requirements were identified. Thanks to a business partnership with temporary supplier of chillers, Aggreko, Star was able to deliver the specialist temporary temperature controlled solution to site within a short time frame. Aggreko provided 2 off VLTC chillers for approximately 150kW of cooling to below -300C, two off heat rejection air cooled chillers, a special LT heat exchanger which was connected into the customer’s process line, circulation pumps, a buffer tank and generators. 

    Dr. Rudolph Prince, Head of Engineering at AGC Chemicals Europe, said, “The thing that really impressed us about Star was the speed in which they reacted to our situation. We needed the equipment on site as soon as possible so we could start up production again with minimum disruption. It was all coordinated over the weekend, and the temperature solution allowed us to be fully operational again within a few days so we didn’t suffer from further downtime.”

    Furthermore, the chemical plant found that the temporary refrigeration equipment was much more efficient than their fixed site equipment. Star’s selection of the right temporary solution for the site capacity and temperature requirements delivered a more effective cooling process, allowing for a larger output of product than the plant it replaced. This allowed the site to catch up with the back log of production from the downtime very quickly once they were operational again.

    Now that AGC Chemicals are aware of Star Refrigeration’s expertise, the companies are likely to form a long term partnership. Star has already delivered a second temporary solution with Aggreko elsewhere on site, and there is scope for consultation on overall site requirements.

    In terms of future work at the plant, Star plan to ensure AGC’s  peace of mind by protecting their business operations-should the unthinkable happen-with Star’s Refrigeration Temperature Control Contingency Plan Scheme. This will help the site prepare better for future refrigeration equipment failures. AGC Chemicals will turn to Star for any future equipment installation needs, with Star’s technical consultants, STS, ready to undertake a full site survey and produce a technical specification for a new installation to replace the time served plant.

    This successful project highlights how Star Refrigeration’s UK branch network can provide expertise and a rapid response in an industrial emergency situation. While the equipment failure was unwelcomed by AGC Chemicals Europe, it provided an opportunity for the company to see how more efficient technology could benefit them in the long term, both economically and environmentally.

    For more information on Star’s preventative services and contingency planning visit /news/chiller-contingency-planning-for-critical-cooling-situations-keeps-star-refrigeration-customers-cool.aspx


  • Star Maintenance


    Operating and maintenance typically contributes to more than 80% of the life cycle cost of refrigeration plant. When selecting new plant, emphasis is often placed on purchasing the most efficient design but this does not guarantee low running costs. Pro-active maintenance is key to ensuring the plant continues to operate at its design parameters throughout its life.

    Star Refrigeration’s operations team is focused on ensuring our customers have plant that operates efficiently and reliably throughout the year. Our nationwide network of nine branch offices are fully staffed with experienced management teams and we have more than 80 mobile field engineers to support your business.

    Our aftercare team continuously reviews plant performance against design parameters to ensure the lowest possible running costs for our customers. We look for ways of improving performance from simple changes to operating parameters through to the retrofitting of new energy enhancing technology to existing systems.
    Examples include:

    • Application of inverter technology (compressors, condenser fans, pumps)
    • Defrost on demand
    • Automatic oil recovery
    • Electronic expansion valves

    We work closely with our customers to develop a proactive maintenance programme, tailored to their needs. When undertaking a new contract, we review the existing equipment and provide a free of charge plant review that highlights areas for action to bring the plant back to design and suggestions for improving reliability and efficiency. These are then developed into an action plan that is reviewed regularly with our customers.

    Our Telstar control system enables offsite monitoring of plant faults and alarms. More recent installations also include maintenance alerts which detect movement away from the plants design conditions. These provide early warning of reduction in efficiency and potential future problems, enabling our engineers to attend site to resolve before a problem occurs.

    Our proactive approach to maintenance is effective in reducing life cycle costs and is demonstrated in data measured by our customers. Below are examples of how the Star approach to maintenance has reducing operating costs for two customers.

    Case Study 1 - Temperature Controlled Distribution Centre

    This multi-temperature distribution store was completed in 2006 and has a two stage central ammonia refrigeration system installed by a competitor. The plant consists of three high stage screw compressors, two low stage reciprocating compressors, two evaporative condensers and 20 evaporators in three temperature controlled chambers. Following an 18 month maintenance period with the original installer Star took over in February 2008. Following a full site survey, modifications were made to reinstate the plant back to its design conditions. We made a number of zero cost changes to the plant control to enhance operating efficiency and improve store temperatures. Refrigerant was also added to the plant as the survey found it was running undercharged. This improved both efficiency and reliability.

    An energy monitoring system installed on site has provided detailed energy data since the plant was installed. The graph below compares running costs from 2007 and 2008. A comparison of plant running costs over 12 months indicates an average energy saving of 100,000kWhr per month since Star took over the site maintenance contract. This corresponds to a saving of £6,000 per month based on an energy costs of 6p/kWhr. Data for 2009 is following the same trend as 2008, underlining our ability to reduce and preserve operating cost savings.

    Case Study 2 – Brewery

    Star has recently completed modifications to an existing brewery maintenance customer’s cooling system to enhance operating efficiency. The customer has three modular water cooled plants as indicated in the following diagram:

    Star modified one of the three systems, installing a new inverter controlled reciprocating compressor package (in place of the original fixed speed machine). A new compressor sequencing system was also installed to supervise the starting and stopping of all three systems. This has resulted in a £2,000 per week reduction in running costs and a payback of less than 2 years on the investment.