Rhyddings High School, Oswaldtwistle
Phased Heating System UpgradeVital Synergy delivered a phased renewal of Rhyddings High School's ageing heating system, replacing a worn LTHW distribution network, pumps and controls while retaining the school's existing boiler plant through a new hydraulic separation strategy. The works resolved long-standing gas safety and ventilation issues, introduced a modern Building Management System, and restored consistent, reliable warmth across the campus, all delivered through a programme of evening, weekend and holiday working that kept disruption to the live school to a minimum.
Client Overview
Constructed in the 1930s, Rhyddings High School in Oswaldtwistle relied on two ageing Remeha boilers connected to a worn distribution network of pipes and radiators. Leaks, uneven heating and outdated controls left classrooms cold, while gas safety and ventilation in the boiler house no longer met current standards, prompting the school to commission a full renewal of its heating system.
Delivering a major mechanical upgrade inside a live secondary school demanded careful sequencing around the academic calendar. Enabling works were confined to evenings, weekends and holiday periods, and continuous coordination with school leadership kept disruption to lessons and assemblies to a minimum throughout the programme.
A new 720kW plate heat exchanger decoupled the existing Remeha boiler circuit from an entirely new pressurised low-temperature hot water distribution network. Insulated steel pipework and modern control valves were installed across the school in carefully zoned circuits, with all radiators replaced by high-output units and fan convectors fitted with integrated smart controllers.
Twin-headed Grundfos Magna pumps were sized and installed for each heating zone, providing redundancy and variable-speed flow control. A new pressurisation unit and multiple expansion vessels, including a 300-litre vessel, stabilised the sealed system, while a new electronic gas safety interlock and upgraded boiler house ventilation brought the plant room fully into compliance.
A modern BMS was deployed to centralise scheduling, temperature set-points and holiday set-backs, integrating gas leak detectors, boiler and pump status alarms, and an automated summer/winter mode switch. The system gives facilities staff remote visibility and fine control over every heating zone, with immediate alerting of any faults.
Every control point and safety interlock was tested against detailed I/O schedules, with the gas safety enhancements validated alongside the regional gas network operator. Full asset registers, as-built drawings and commissioning certificates were handed over alongside dedicated on-site training for the school's facilities team.
Key Outcomes and Benefits
Hydraulic separation decoupling the existing boiler plant from an entirely new pressurised LTHW distribution network.
A new electronic gas interlock system and upgraded boiler house ventilation resolved all identified safety risks.
Phased, holiday-led delivery kept the school heated throughout, with no unplanned classroom downtime.
Centralised scheduling, monitoring and fault alerting now cover every heating zone across the school.
Additional resource and re-sequencing brought the project back on track for full commissioning before term started.
High-output radiators and fan convectors deliver balanced, responsive heating across every classroom and hall.
Project Detail
As works progressed inside a live, occupied secondary school, sequencing and safety governed every stage of delivery. Enabling works were carried out during evenings and weekends, with the most disruptive strip-out and installation activity confined to school holidays and phased block-by-block to keep parts of the building heated throughout.
Close coordination with school leadership and the client's consultants kept construction sequencing aligned with the academic calendar, while a dedicated making-good team followed installation crews to restore ceilings and finishes and keep the site safe and tidy.
Compliance and Safety
A new electronic gas safety interlock system and improved boiler house ventilation were installed in accordance with current regulations, supported by gas leak detection integrated into the BMS. The interlock system and detectors were tested in cooperation with the regional gas network operator to secure the required compliance certification.
Site-specific health and safety procedures and controlled access systems were maintained throughout, with particularly disruptive tasks such as core drilling and plant room works scheduled for evenings or holiday periods to protect staff and students.
Programme and Delivery
When unforeseen challenges, including material lead times, slowed progress mid-project, Vital Synergy implemented a programme recovery plan, mobilising additional skilled tradespeople and re-sequencing tasks to regain lost time. The project entered its final five-week completion phase by late June 2025, with all major works on track.
Finishing touches, including pipework lagging, control system finalisation and sports hall upgrades, were completed during the first two weeks of the summer break, allowing thorough testing and commissioning before staff and students returned for the new academic year.
Technical Scope Summary
A summary of the key systems upgraded across the project:
This was a complex, phased upgrade, but Vital Synergy kept disruption to an absolute minimum throughout. The new BMS and pumps have made a noticeable difference to reliability, and their attention to gas-safety compliance gave us complete confidence.
Site Manager, Rhyddings High School
