TM44 Revealing Hidden Energy Waste

The challenge

What the TM44 Inspection Uncovered

The TM44 inspection did not find a broken building. It found a building quietly haemorrhaging money, risk and carbon — in ways that are almost impossible to see without specialist diagnostic tools.

Ageing refrigerants: financial and environmental risk Two systems still running on R22 — a banned ozone-depleting refrigerant — carried an estimated £2,421 per year in avoidable running costs. The risk of a refrigerant leak event and its financial and regulatory consequences was significant.

Inefficient R410A equipment driving unnecessary energy use Multiple units running on older R410A refrigerant showed low SEER ratings and no inverter control, contributing an estimated £3,114 per year in excess energy cost. These systems were working harder than necessary to deliver the same result.

No AC scheduling or temperature strategy Most systems were being switched on manually with no timers or seasonal setpoints. Optimised scheduling alone is projected to save £1,328 per year — a cost that had been accumulating unnoticed for years.

Maintenance gaps and insulation deterioration External insulation on 11 of the 12 systems showed cracking or decay, reducing thermodynamic performance and quietly increasing the energy needed to maintain comfort.

The solution

A Compliance Programme That Became a Strategy

Smart Projects delivered a combined compliance and optimisation programme that reframed how Transvac manage their HVAC assets — moving from a once-every-five-years obligation to an ongoing improvement strategy.

TM44 Inspection and Full HVAC Diagnostic

Using CIBSE TM44 methodology, Smart Projects assessed all 12 systems and produced a clear, evidence-based picture of performance, compliance status and financial risk. The diagnostic identified R22 systems requiring urgent decommissioning, oversized and non-inverter units using excessive energy, systems not meeting Minimum Energy Performance Standards, missing control schedules and inefficient setpoints, and refrigerant types contributing 59 tonnes CO₂e of site GWP.

Enhanced Air-Conditioning Maintenance Programme

To act on the TM44 findings, Smart Projects introduced a structured maintenance plan tailored to the age and condition of each system. This included comprehensive deep cleans of internal and external coils, replacement of degraded insulation to restore thermal performance, F-Gas compliance, leak checks and creation of site logbooks, controller calibration and seasonal setpoint optimisation, and ongoing performance monitoring to identify efficiency drops early.

Once Transvac saw their building as a dynamic system rather than static equipment, decisions became easier. Maintenance shifted from "something we do when it breaks" to a strategic tool for reducing cost, risk and environmental impact.

The result

✓  Improved System Efficiency

Cleaner coils, correct insulation and controlled setpoints stabilise temperatures and reduce kWh use.

✓  Reduced Operating Costs

A measurable £6,863 annual improvement based on data taken directly from the TM44 report.

✓  Reduced Equipment Risk

Reduced risk of catastrophic refrigerant leakage, lower likelihood of unplanned failures, and avoided unnecessary capital expenditure.

✓  Lower Carbon Footprint

Targeted upgrades cut refrigerant-related emissions and support wider environmental goals.

✓  Greater Compliance and Control

Smart Projects' maintenance plan ensures leak checks, documentation and performance monitoring are always up to date.

✓  Extended Equipment Life

Consistent maintenance prevents the accelerated degradation that comes from neglect, protecting asset value.