Venting more was never going to work.
Above: system illustration from our report to the client, used to show what needed to change.
INDUSTRIAL · DENMARK · 2026
Commissioning support, troubleshooting and air separation · Client anonymized to protect client confidentiality
A new industrial chilled water system was stuck at commissioning. The inspector required less than 4% air by volume, and after a week of trying, the system would not get there.
01 · The problem
During startup and commissioning of a new chilled water system, the contractor could not get the air out. The inspector's test required less than 4% air by volume before commissioning and handover could proceed. The project had been stuck for a week.
02 · What we found
The system had small automatic air vents, but no proper air separator on the main circuit. Small vents only release free air pockets. Air that is entrained in the water stays in circulation and never reaches them. On top of that, the method used to fill the system was introducing and trapping air from the start.
03 · What we did
We wrote a short, correct fill and venting procedure for the team. Following it brought the system under 4% air and through the inspection. For the long term, we recommended a full air separator on the main circuit. The end user wanted the system to be fully serviceable, and valued reliability over the small added cost, so the separator was installed as the permanent fix.
04 · The result
The system passed the air test, and commissioning and handover went ahead. With the air separator in place, it stays air-free and serviceable for the long term.
"We don't do so much of this work. Thank you for helping us on such short notice. We have been stuck for a week on this."
Client · Industrial contractor (anonymized)
Venting more was never going to work. The air was in the water, not in the pipes. The right procedure solved the deadline. The right equipment solved it for good.