Case Study
Boiler Plant Replacement at Internationally Renowned Health & Wellness Provider
Overview
Client: Internationally Renowned Health & Wellness Provider
Industry: Leisure & Health Clubs
Presence: Boiler Replacement, Temporary Boiler Hire, Mechanical Installation, Pipework Integration, Commissioning
Project Overview: Newsome completed a full boiler plant replacement for a leading health and wellness provider, installing a new 900kW cascade boiler system while maintaining uninterrupted heating and hot water services throughout the project. The new high-efficiency solution improved energy performance, operational flexibility and long-term reliability, demonstrating Newsome’s ability to deliver temporary rental support, mechanical installation and capital replacement projects as a single turnkey service.
Newsome successfully delivered a complete boiler plant replacement project for an internationally renowned health & wellness provider, providing a modern, energy-efficient heating solution while maintaining uninterrupted hot water and heating services throughout the installation period. The project involved replacing the club’s ageing boiler infrastructure with a new high-efficiency cascade boiler system designed to improve operational flexibility, increase system resilience and deliver improved energy performance across the site.
Operating within a live leisure environment presented a unique challenge. Maintaining continuous heating and domestic hot water provision was critical to protecting member experience and ensuring the facility remained fully operational throughout the works. To achieve this, Newsome designed and delivered a phased installation strategy supported by temporary boiler provision and detailed project coordination. This project demonstrates Newsome’s ability to combine consultancy, temporary rental capability, mechanical installation expertise and long-term capital replacement solutions within a single turnkey delivery model.
The Challenge
Following a recent service visit, it was identified that the existing boiler plant serving the facility had reached the point where replacement was required to maintain long-term reliability and operational performance. The existing system consisted of two primary boilers providing industrial heating and supporting domestic hot water requirements across the club environment. As with many occupied leisure facilities, the project presented a significant challenge. Heating services could not simply be switched off while replacement works were undertaken.
The site required an approach that maintained business continuity throughout the programme while allowing safe removal of existing equipment and installation of a completely new heating infrastructure.
In addition to maintaining operational continuity, the replacement solution needed to improve flexibility, support more efficient operation under varying demand conditions and deliver improved resilience for future operation.
Why They Chose Newsome
Projects of this nature require considerably more than equipment supply alone. The client required an engineering partner capable of delivering consultation, temporary support, detailed mechanical design, installation management, commissioning and long-term service capability. Newsome’s ability to support both temporary rental and permanent capital solutions created a significant advantage throughout the project. Our team was able to develop a complete replacement strategy while simultaneously planning temporary heating provision to maintain uninterrupted operation throughout installation.
By managing all stages internally, including project management, mechanical installation, boiler integration, commissioning and future service support, Newsome provided a single point of responsibility and reduced operational risk for the client. This one-stop-shop approach enabled the project to progress efficiently while maintaining full control over quality, programme delivery and operational continuity.
Developing a Resilient Heating Strategy
Rather than replacing the existing arrangement with another traditional large boiler installation, Newsome designed a modern cascade heating system based around six high-efficiency condensing boilers. The new plant comprised six IDEAL Evomax II boilers, each providing up to 150kW output, delivering a combined heating capacity of 900kW.
The cascade arrangement was selected specifically to improve operational flexibility and efficiency. Unlike traditional boiler configurations, cascade systems allow heating output to closely match real building demand through staged operation and intelligent modulation. As heating requirements fluctuate throughout the day, boilers automatically stage on and off to maintain efficient operation while reducing unnecessary energy consumption. This arrangement also provides greater resilience. Should one individual boiler require maintenance or experience a fault condition, remaining boilers continue operating to maintain building services.
Maintaining Operations Through Temporary Boiler Support
One of the most critical elements of the project was maintaining heating and domestic hot water throughout installation. Newsome developed a phased installation strategy designed to minimise disruption and maintain operational continuity throughout the replacement works.
Where practical, existing plant was retained in service during the initial stages of installation. However, contingency arrangements were also incorporated through temporary boiler provision to ensure uninterrupted operation if full plant shutdown became necessary. Temporary boiler equipment was mobilised and prepared to support the site load where required, including temporary gas infrastructure, heating pipework and full installation support. This approach allowed installation activities to proceed efficiently while ensuring uninterrupted service to showers, taps, heating systems and wider building operation. The combination of temporary rental capability and permanent capital delivery demonstrates one of Newsome’s core strengths, allowing clients to maintain continuity while modernisation works are completed.
High Efficiency Boiler Technology
The selected boiler solution was based around the IDEAL Evomax II range of compact wall-standing condensing boilers. These units were selected for their combination of high seasonal efficiency, compact footprint and operational flexibility.
With seasonal efficiency approaching 97%, low NOx emissions and advanced modulation capability, the new system provides substantial improvements over traditional boiler plant arrangements.
The modular nature of the installation also allowed the system to be delivered within the constraints of the existing plantroom while creating additional space for servicing and future industrial boiler maintenance activities. Integration with building controls also provides future opportunity for weather compensation and floating temperature operation, allowing the heating system to adapt dynamically to changing environmental conditions and occupancy patterns.
Mechanical Installation and Plantroom Integration
The installation phase required careful planning due to restricted plantroom access and the complexity of integrating new equipment into the existing infrastructure. To minimise disruption and improve logistics, existing boiler equipment was decommissioned, mechanically isolated and removed in a controlled sequence. Existing plant was dismantled into smaller sections where necessary to facilitate removal through segregated routes. New boilers were delivered and installed in a phased approach, allowing efficient positioning within the available plantroom space.
Newsome’s mechanical installation teams completed all new pipework integration using appropriately sized distribution pipework connected via a plate heat exchanger arrangement and linked into the existing secondary system. New valves, isolation arrangements, filtration and control components were incorporated throughout the installation to improve long-term serviceability and operational control. All new pipework was insulated to match existing specifications, with maintenance components fitted with removable insulated covers to support future service access.
Commissioning and Long-Term Reliability
Following installation, the complete heating system underwent comprehensive commissioning by Newsome service engineers. This included pressure testing, venting, hydraulic balancing, control verification and operational performance testing to ensure the new system performed in accordance with design requirements. Particular attention was given to maintaining system water quality and ensuring the primary heating circuit was fully protected to support long-term operational reliability and equipment longevity.
Once final commissioning was completed, temporary support systems were removed and the new boiler infrastructure transitioned into full operation.
The Outcome
The completed project has provided a modern, resilient and highly efficient heating infrastructure capable of supporting the facility for years to come. By replacing ageing plant with a modular cascade boiler arrangement, Newsome has improved operational flexibility, reduced energy demand and strengthened long-term heating resilience across the site. Most importantly, the project was delivered while maintaining uninterrupted building operation and protecting member experience throughout installation.
This project highlights Newsome’s ability to combine temporary rental expertise, permanent capital delivery, engineering design, installation and ongoing support to provide complete HVAC Systems and heating solutions for complex occupied environments.