Case Study






R22 Replacement


£5 million


PROjEN have been providing a professional Project Management service for GSK since 2002 and have been involved in the delivery of over 200 Capital projects with a value in excess of £100 million. The project aim was to increase cooling capacity and replace ozone depleting HCFC based chillers at their Stevenage site to meet the increase in demand for cooling and conform to Montreal protocol.

The Project Scope

The project, for which PROjEN were awarded the ECI Active Project of the Year Award in 2004 for their management of the overall project, saw the replacement of two existing chiller units with two state of the art, 1 MW, chiller packages of higher capacity and efficiency.

The key benefits of PROjEN’s project delivery included:

  • The successful removal of R22 before European Legislation intervention and in compliance with GSK policy – delivered within budget and on time
  • Increased Heat Transfer Fluid capacity from 150 to 253 m3/hr and increased cooling capacity from 1500 to 2000kW
  • Increased the number of modules serviced simultaneously from 8 to all 12, and increased efficiency by 15% over previous plant performance.

The Challenges

The main challenge on this project was that the original shut down availability was reduced from six to four weeks. This was an incredibly short timescale, however the project was managed in such a way that this didn’t become a major issue.


This GSK project was highly critical to GSK’s future production and it was imperative that deadlines were kept to and the performance criteria were met. Despite the many difficulties encountered along the way, GSK were delighted with the outcome. A key factor was the working culture of both businesses with the focus being on getting the job done.

Project Cost

£5 million


10 months




  • We utilised existing plant and equipment where possible and minimised disruption to pilot plant operations.
  • All major work was also carried out within a shutdown period of just 30 days.
  • The new HTF pumps and improved control systems were integrated with the existing package.


GSK commented: ” The project demanded a high level of competence from all parties involved and the incentives employed by PROjEN created a clear awareness of the importance of Health & Safety. As such, the project was completed on time and to budget without any major incidents.”